305B97003
vvEPA
United States Enforcement & Compliance Assurance EPA 305B-97-003
Environmental Protection (2225-A) September 1997
Agency
Multimedia
Compliance/
Pollution Prevention
Assessment
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MULTIMEDIA COMPLIANCE/POLLUTION PREVENTION ASSESSMENT
GUIDANCE FOR SCREEN PRINTING FACILITIES
U.S. Environmental Protection Agency
Office of Enforcement and Compliance Assurance
1200 Pennsylvania Avenue, N.W.
Washington, DC 20044
August 4, 1997
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NOTICE
The statements in this document are
intended solely as guidance. This
document is not intended, nor can it
be relied on, to create any rights
enforceable by any party in litigation
with the United States. EPA and State
officials may decide to follow the
guidance provided in this document, or
to act at variance with the guidance,
based on an analysis of specific site
circumstances. This guidance may be
revised without public notice to reflect
changes in EPA's policy.
Mention of trade names or commercial
products in this document or associated
references does not constitute an
endorsement or recommendation for
use.
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TABLE OF CONTENTS
Page
Introduction ii
1. Screen Printing Industry Profile 1
2. Screen Printing Processes, Materials, and Wastes 3
2.1 General Overview of Printing Processes 3
2.2 Screen Printing Process Summary 4
2.3 Image Processing (Prepress) 6
2.4 Stencil and Screen Preparation (Prepress) 9
2.5 Printing Operations (Press) 11
2.6 Finishing (Postpress) 16
2.7 Screen Reclamation (Postpress) 16
3. Assessment Protocol 22
3.1 Pre-Assessment Preparation 23
3.2 On-Site Activities 23
3.3 Preparation of Assessment Report ... 27
3.4 Follow-Up Activities 27
LIST OF TABLE
Table 1. Screen Printing: Waste Streams of Concern 7
Table 2. Traditional Screen Reclamation Chemicals 18
LIST OF FIGURE
Figure 1. Screen Printing Processes: Raw Materials and Wastes 5
LIST OF APPENDICES
Page
Appendix A. Multimedia Compliance/Pollution Prevention Assessment Checklist for
Screen Printing Facilities A-l
Appendix B. Multimedia Compliance/Pollution Prevention Assessment Report Form
for Screen Printing Facilities B-l
Appendix C. Annotated Bibliography of Selected References C-l
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INTRODUCTION
Statement of Goals:
This document was developed to assist field personnel in state, local, and EPA regional
offices in conducting multimedia assessments of screen printing facilities. Its primary goal is
to enable inspectors to fulfill the traditional role of assessing the compliance status of
individual facilities by providing specific information about the screen printing process and a
corresponding assessment protocol. However, the manual also focuses on the important goal
of overall unproved environmental quality by approaching the assessment process with the
added objectives of providing compliance assistance to facilities and identifying pollution
prevention opportunities.
Section Overview:
To familiarize the inspector with the screen printing industry, Chapter 1 first presents a
screen printing industry profile that provides background demographic information on the
printing industry in general as well as the screen printing sub-sector. Chapter 2 describes the
various processes and materials that are used hi the screen printing industry and the wastes
that are generated. Actual processes will vary from plant to plant, but this section will
introduce the inspector to the fundamental operating principles of a typical facility. Finally,
Chapter 3 is an assessment protocol which accompanies the assessment checklist and provides
procedural guidance for inspectors regarding regulatory compliance and pollution prevention
techniques hi the screen printing industry.
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CHAPTER 1
SCREEN PRINTING INDUSTRY PROFILE
Screen printing is one of five common printing processes that comprise the printing
industry. The industry as a whole is classified as Standard Industrial Classification (SIC)
Code Major Group 27—Printing, Publishing, and Allied Industry. Major Group 27 includes
firms engaged in printing by one or more common processes, such as screen printing, as well
as those entities that perform printing related services, such as bookbinding, typesetting, and
photoengraving. It also encompasses firms that publish newspapers, books, and periodicals.
The SIC subgroups under 27 include the following:
271 - Newspapers
272 - Periodicals
273 - Books
274 - Miscellaneous (e.g., atlases, maps, calendars)
275 - Commercial Printing
276 - Manifold business forms
277 - Greeting cards
278 - Blankbooks, Looseleaf Binders, and Bookbinding and Related Work
279 - Service Industries for the Printing Trade (typesetting, platemaking and
related services).
Five printing processes currently dominate the U.S. printing industry, accounting for
97 percent of its output. They are, hi order of market share, lithography, gravure,
flexography, letterpress, and screen printing.1
Screen printing is the smallest of the five and differs from other printing processes in
that stencils and screens, rather than plates, are used to transfer the image. It is also
considered to be the most versatile of the printing processes and is applicable to a wide range
of substrate materials, including textiles, plastics, papers, fabrics, wood, leather, glass, and
ceramics. Screen printing is also used to manufacture electronic printed circuit boards.
'U.S. EPA. Printing Industry and Use Cluster Profile. 1994.
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There are few restrictions on the size or shape of the screen printed product, as there are for
other printing techniques. The process also allows greater thicknesses of ink to be deposited
on the substrate, thus creating brighter colors and more durable substrates.
Currently, screen printing comprises approximately 3 percent of the commercial
printing industry. However, this figure does not include the large number of "captive in-
plant" presses that operate as part of a production line for a variety of products. For
example, a toothpaste packaging line might incorporate a screen printing process to print the
outside of the toothpaste tube. The exact number of facilities is therefore difficult to
determine, but the Screenprinting and Graphic Imaging Association International (SGIA)
estimated the total number of facilities at about 40,000 hi then: 1990 Industry Profile Study.
Of the 40,000 screen printing facilities, approximately half are engaged hi the printing of all
types of textiles, while the other half are engaged hi the production of graphic (non-textile)
applications, such as decals, labels, membrane switches, and billboards. The average U.S.
screen printing facility employs approximately 20 employees represented by 14 production
workers, 2 managers or supervisors, 2 sales personnel, and 2 other personnel. Textile
facilities tend to be somewhat smaller, employing on average 15 or fewer employees. Large
plants with more than 100 employees also exist, but are few hi number and account for less
than 3 percent of screen printing facilities.2 The gross sales hi 1986 for the screen printing
industry were estimated by SGIA at $13.7 billion hi their 1990 Industry Profile Survey.
More than 50 percent of the facilities have gross sales of less than $1 million.
2U.S. EPA. Printing Industry and Use Cluster Profile. 1994.
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CHAPTER 2
SCREEN PRINTING PROCESSES, MATERIALS, AND WASTES
2.1 General Overview of Printing Processes
Printing processes are identified by the method of image transfer and by the type of
image carrier employed. Printed images are transferred to the substrate either directly or
indirectly. A substrate is any material upon which ink is deposited. Direct printing
processes are gravure, flexography, letterpress, and screen printing. In direct printing, the
image is transferred directly from the image carrier to the substrate. In indirect, or offset,
printing, the image is first transferred from the image carrier to an intermediate blanket
cylinder and then to the substrate. A discussion of individual printing processes and the
products associated with those processes is presented below:
Lithography is a form of printing that employs planographic plates, in which
the images are neither raised hi relief nor depressed. Instead, the flow of ink
is controlled by coatings on the plate with different physicochemical
properties. Lithography is the predominant printing process in the United
States and accounts for approximately 50 percent of all printing applications.
Sheet-fed lithography is used for printing books, posters, greeting cards,
labels, packaging, advertising flyers, brochures, periodicals, and for
reproducing artwork. Web offset lithography is used for periodicals,
newspapers, advertising, books, catalogs, and business forms.
Gravure printing makes use of intaglio plates, hi which ink is contained hi
depressions etched onto the surface of the plate. It is used for large volume
runs and high speed runs for printing high-quality publications, magazines,
catalogs, and advertising. It also has large volume applications in the printing
of flexible packaging, paperboard boxes, and labels.
Flexography is a form of letterpress that uses a flexible plastic or rubber plate
hi a rotary web press. Flexography is a relief printing process, hi which the
image is raised above the surface of the plate. It is used primarily for
packaging (plastic wrappers, corrugated boxes, milk cartons, foil, paper bags)
and for imprinting large surface areas. The use of flexographic printing
techniques has increased with the amount of packaging used in the United
States.
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• Letterpress printing is the original relief printing process. Web letterpress is
used for some printing of newspapers and magazines. However, its use is
declining as the use of lithographic printing increases. Sheet-fed letterpress is
used for some books, printed stationery, announcements, business cards, and
advertising brochures. Because individual changes can be made on a plate
without having to redo the entire plate, letterpress is particularly useful for
price lists, parts lists, and directories.
• Screen printing can print on virtually any substrate, including wood, glass,
fabrics, plastics, and metals. It is used for specialty printing such as T-shirts,
posters, banners, decals, and wallpapers. This type of printing makes up a
small but growing segment of the printing industry. Screen printing is also
used to print patterns on electronic circuit boards prior to etching.
Each of the printing processes can be divided into three major steps: prepress, press,
and postpress. Prepress operations involve a series of steps during which the idea for a
printed image is converted into an image carrier (i.e., printing plate, cylinder, or screen).
Press operations are the actual printing step, in which the ink is transferred via the image
carrier to the substrate. Drying or curing of the ink is also usually classified as a press
operation. Postpress involves various finishing operations to prepare the product for
delivery to the customer and cleaning operations to prepare the equipment for the next
printing run.
2.2 Screen Printing Process Summary
Screen printing differs from other printing processes primarily in that the image
carrier is a screen-mounted stencil, rather than a plate. Screen printing consists of five
processes—image processing, stencil and screen preparation, printing, finishing, and screen
reclamation—each of which can be identified as part of the prepress, press, or postpress
steps. Figure 1 illustrates the sequence of activities involved in a typical operation and notes
the raw materials and wastes associated with each process.
Prepress. Prepress operations typically involve image processing by
photographic processes, followed by stencil and screen preparation, in which
a stencil is created in the shape of the non-image area and is mounted onto a
prepared screen. For multi-color printing, a separate stenciled screen is
prepared for each color of ink that will be used.
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Raw Materials
Wastes
Film
Developer
Fixer
Screen
Fabric
Stencil Material
(lacquer/emulsion/
photosensitive film)
Ink/ink additives
Substrate
Spray adhesives
Heat/UV Light
Cleaning Solvents
(Ink remover, emulsion remover,
haze remover, degreaser)
Waste Film
>• Used Developer
Used Fixer
>• Wastewater
>• Waste stencil material
Wastewater
Waste ink/ink additives
Waste substrate (misprints)
VOC emissions
Empty ink containers and aerosol cans
Wastewater
>• VOC emissions
Waste Trimmings
Ink Residue
Spent Cleaning Solutions
VOC Emissions
Wastewater
Figure 1. Screen Printing Processes: Raw Materials and Wastes
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Press. During the press, or printing, step, the substrate (e.g., a T-shirt), is
passed under the stenciled screen. A rubber squeegee is swept across the top
surface of the screen to press the ink through the areas of the screen that are
imaged. In this way, ink is transferred only to the image areas of the
substrate. In a multi-color printing press, the substrate is passed in sequence
through a series of single-color stenciled screens, one for each color of ink.
Postpress. Postpress operations will involve various finishing operations,
depending on the product. These finishing operations include assembly, die
cutting, or guillotine cutting of screen printed parts. For screen printers,
postpress activities also include reclamation of the screen material after the
printing run.
Primary waste streams of concern in a screen printing facility include the various
hazardous compounds found in spent photoprocessing solutions and VOC emissions resulting
from the use of inks and cleaning solvents. Table 1 lists these and other waste streams of
concern in a typical screen printing facility and summarizes the environmental issues
associated with their control.
The five major processes—image processing, stencil and screen preparation, printing,
finishing, and screen material reclamation—are discussed in greater detail in the following
sections.
2.3 Image Processing (Prepress)
The screen printing process usually begins with the image processing step to transfer
the original camera-ready art into one or more images on black-and-white film. This film
positive image is subsequently used to create a photostencil. It can be made of paper, plastic
film, or a glass base and is covered with a light sensitive coating. This coating is usually
composed of silver halide salts (silver chloride, silver bromide, and silver iodide). To create
the film positive, the original art is photographed, which exposes the film to the image.
After the film coating has been exposed, it must be developed. The traditional film
developing process consists of immersing the exposed film in a developer bath, a fixer bath,
and finally a rinse bath. Immersion in the developer solution converts the silver halides to
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Table 1. Screen Printing: Waste Streams of Concern
(adapted from Washington State Department of Ecology, Environmental Management,
and Pollution Prevention: A Guide for Screen Printers, 1994)
Waste Stream
Aerosol Cans
Developer
Fixer
Haze Remover
Ink Remover
Emulsion Remover
Parts Washer Solvent
Scrap Film
Screen Degreaser
Waste Screen Emulsion
Shop Towels
Waste Ink
Area of Concern
Hazardous Waste
Air Quality
Hazardous Waste
Wastewater
Hazardous Waste
Wastewater
Hazardous Waste
Wastewater
Hazardous Waste
Air Quality
Wastewater
Hazardous Waste
Solid Waste
Hazardous Waste
Air Quality
Wastewater
Hazardous Waste
Air Quality
Hazardous Waste
Air Quality
Environmental Concern
"Listed" chemicals'
VOCs
Hydroquinone
High silver
High pH
"Listed" chemicals2
"Listed" chemicals
VOCs
Heavy metals3
High pH
Reactivity
"Listed" chemicals
Disposal of recoverable silver
"Listed" chemicals2
VOCs
Suspended Solids
Improper disposal of inks and
solvents
"Listed" chemicals
VOCs
Heavy metals3
'Listed chemicals include the following chemicals:
acetone
benzene
carbon tetrachloride
chlorinated fluorocarbons
chlorobenzene
cyclohexanone
2-ethosyethanol
ethyl ether
isobutanol
2Formulations for haze remover
readily available.
methanol
methylene chloride
methyl ethyl ketone (MEK)
methyl isobutyl ketone (MffiK)
n-butyl alcohol
2-nitropropane
ortho-dichlorobenzene
pyridine
and screen degreaser that do not
tetrachloroethylene
toluene
trichloroethylene
1,1,1-trichloroethane
1,1,2-trichloroethane
1,1,2-trichloro-1,2,2-
trifluoroethane
trichlorofiuoromethane
xylene
contain listed chemicals are now
Conventional, solvent-based ink systems are more likely to contain some amounts of heavy metals
such as barium, cadmium, chromium, or lead.
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metallic silver on the film. Developers typically contain benzene derivatives, along with an
accelerating agent (to speed up the developing process), a preservative (to reduce oxidation
damage to the developer), and a restrainer (to prevent image "fogging").
The developing action is stopped by a fixing bath. Each time a photographic image is
immersed hi a fixing bath, a small amount of silver enters the bath from the film coating.
Insoluble compounds that are formed after the silver concentration reaches a certain level
cannot be removed from the coating, so the fixer must be diluted prior to reaching this level.
The critical silver concentration for fixing baths is 0.27 ounces per gallon (2 grams/liter).
After the image has been fixed, the film is washed to prevent residual chemicals from
reacting and damaging the image. Washes are usually water, with a temperature of 80°F
(27°C) and a pH of 4.9 or higher. In some photoprocessing, chemicals are applied to the
film coating to reduce or increase the image contrast. Reducers act by oxidizing some of the
silver; intensifiers add silver or mercury to the developed silver grains in the coating. Image
processing wastes typically include spent developer, spent fixer, contaminated wash water,
silver, waste film, and associated photodeveloping chemicals.
As an alternative to the traditional tray system of developing film, most screen
printers now use a diffusion transfer film developing unit. These self-contained units require
less labor and produce considerably smaller amounts of photographic chemical wastes. The
film positive and film negative sheets are fed together through a roller system and
automatically exposed to light and to a developer solution. No fixer is needed for this
process before the rinsing step.
Silver Recovery from Used Fixer
The silver content hi spent fixer has value and can be recovered. On-site recovery of
silver is most likely to be practical for larger facilities that generate a significant amount of
used fixer. Several methods exist for extracting the silver. The most common methods for
recycling small amounts of fixer are electrolytic units and metallic replacement cartridges.
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Electrolytic Units. Electrolytic units operate by collecting the positively
charged silver ions on a negatively charged cathode. The resulting silver
deposits are hi a high state of purity and are easily refined and recycled.
Electrolytic units are efficient and effective down to a silver concentration of
about 100 to 300 parts per million (ppm).
Metallic Replacement Cartridges. Metallic replacement cartridges are
hollow canisters that contain steel fibers. When spent fixer is passed through
the canister, the silver precipitates out of solution and some iron dissolves in
its place. Operating costs are greater than for electrolytic units, but treating
silver-bearing wastes with two cartridges in series can, under ideal situations,
reduce the silver concentration to about 1 ppm.
The two technologies can also be combined for optimum silver recovery efficiency.
2.4 Stencil and Screen Preparation (Prepress)
The stencil is the image carrier hi the screen printing process and can be created out
of a photosensitive material. It is affixed to a screen and has a "hole" hi the shape of the
unage to be printed to allow ink to flow through the screen. In the non-image areas, the
flow of ink is blocked by the stencil material.
The screen must have a fine weave to allow ink to be deposited smoothly onto the
substrate. Polyester fabrics are the most common screen material and have largely replaced
the traditional silk screen. Wire mesh and stainless steel screens are also used, but to a
lesser degree. After the screen material is stretched taut over a frame and properly
tensioned, the stencil can be applied to the screen.
Hand-cut Stencil
The simplest method is to manually cut a stencil of the image out of lacquer film.
The cut stencil is bonded to the screen with a liquid adhesive and the paper backing is
removed. This process does not require a film positive image, thus avoiding the generation
of used fixer and other photoprocessing wastes. Hand-cut stencils are not suitable for use
with newer ink systems, however, and their use is becoming increasingly uncommon.
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Photosensitive Stencil
Several methods can be used to create a stencil out of a photosensitive material. All
of them involve exposing a thin fihn of a photosensitive material to light (or ultraviolet light)
through the fihn positive image that was created hi the image processing step. Light passes
through the fihn positive hi the non-image areas and cures the light-sensitive fihn, rendering
it insoluble. The image areas of the fihn are protected from the light source by the film
positive—they can subsequently be dissolved and removed. Three common photosensitive
stencil processes are described below:
Direct Coating Process. A common method hi which a liquid light-sensitive
emulsion is applied to the screen and allowed to dry. The screen is then
exposed to a light source through the fihn positive image, which causes the
emulsion hi the non-image areas of the screen to cure. Several coats of
emulsion can be applied in succession to create more durable stencils. The
emulsion hi the image area remains water-soluble and can be rinsed off with a
pressurized warm water spray, leaving the cured emulsion stencil hi place.
Indirect Film Process. A sheet of photosensitive fihn is exposed to the light
source through the fihn positive, curing the non-image areas. The fihn must
then be developed hi a solution that renders the unexposed areas of the fihn
water soluble. This portion of the fihn is rinsed away, leaving a durable
stencil that can then be bonded to the screen.
Capillary Film Process. A sheet of photosensitive fihn is first laminated to
the screen and then exposed to a light source through the fihn positive. As hi
the indirect fihn process, the fihn must be developed to render the unexposed
areas water soluble and then rinsed with water to remove those areas.
Wastewater containing waste stencil material and adhesives is the primary waste
generated by the stencil and screen preparation processes.
Innovative Technology: Digital Prepress
The rapid advances hi computer technologies in the past decade have resulted hi the
emergence of digital prepress operations. Digital prepress operations eliminate the costly
steps of color separation and photographic production of a fihn positive image. Instead, the
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positive image can be created from a digital file. Digital prepresses now comprise a sizable
(and quickly growing) portion of the screen printer image processing market.
Digital images can be created either directly using a software package designed for
this purpose, or by using a digital scanner. Digital scanners convert an original proof into a
digital file format. Once created, the electronic image can be manipulated into the desired
printing format. The final "camera-ready" image is sent to a raster image processor (RIP)
which converts the file into a usable format for a digital printer. The printer can then print a
high resolution positive image that can be used to create the screen.
The continued development of digital prepress technology has the potential of
reducing the amounts of fixer and other photographic wastes generated hi the screen printing
industry. In addition to digital prepress, digital printers also have the capabilities of printing
directly on many types of substrates, either for the purpose of producing proofs for
inspection, or for printing the actual product in short run applications.
2.5 Printing Operations (Press)
In the printing step, ink is pressed through the stenciled screen and deposited on the
substrate hi the shape of the image. The three types of presses commonly used hi the screen
printing industry are flat-bed presses, cylinder presses, and web presses. Flat-bed presses
and cylinder presses are available hi varying degrees of automation.
Flat-bed Presses
Flat-bed presses are so named because the bed of such presses are horizontal and
parallel to the screen. The substrate to be printed is fed manually or automatically onto the
bed, or table. The squeegee and screen assembly comprise the head, which is lowered onto
the table during the actual printing process. During printing, a single color of ink is applied
to the top of the screen. To deliver the ink through the screen evenly and smoothly to the
substrate, a polyurethane squeegee is drawn over the screen. The head assembly is then
lifted off the table and the printed substrate is removed and replaced with a new sheet.
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Flat-bed presses can be generally classified as clamshell presses or vertical-lift
presses, depending on how the head is lifted off the table. The head of a clamshell press is
hinged on the rear side of the table and is lifted off by a two-post assembly or a drive
mechanism mounted hi the rear of the press. The head of a vertical-lift press is not hinged
to the table. The entire head is lifted off the table by a two-post cantilever or a four-post
assembly.
Carousel presses are a type of flat-bed press used in the textile printing sector. They
consist of several small stations, each used for printing a separate color. The stations are
arranged hi a circular, or carousel, fashion.
Cylinder Presses
Cylinder presses are typically used hi operations where speed or fine detail printing
are a concern. Unlike a flat-bed press, the substrate is not fixed to a horizontal table.
Instead, it is fed across a feedboard and is wrapped around a rotating cylinder. The
squeegee and screen are both located above the cylinder. The squeegee remains stationary at
the top of the cylinder. During printing, the screen moves horizontally between the squeegee
and the cylinder at the same speed at which the cylinder is rotating. Unlike a flat-bed press,
there is no need to lift the head assembly off a cylinder, which allows for printing a greater
number of impressions per hour.
Web Presses
Web presses are used to print continuous rolls of substrate as opposed to individual
sheets. The substrate hi such a press is conveyed continuously across a horizontal bed.
Paper, plastic, or other types of substrates can be used. Unlike a flat-bed or a cylinder
press, the screen of a web press is not flat but is a seamless, rotating metal mesh cylinder
within which the ink is stored. The squeegee is a steel bar inside the cylinder screen which
is pulled snug against the bottom of the cylinder screen. During printing, the substrate is
pulled underneath the rotating cylinder while the steel squeegee delivers ink through the
cylinder screen to the substrate.
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Printing Process
To begin the printing process, a small "makeready" batch is run to ensure that the
images are in good order and are properly aligned. Results from this batch are inspected,
and necessary adjustments are made to the press, colors, or inks. Once the results from the
makeready batch are satisfactory, the actual production is begun to print the desired number
of pieces. Screens generally need to be cleaned occasionally during a production run to
remove any ink that may dry on the screen.
In multi-color printing, a separate screen is required for each color of ink to be
printed. Up to 64 screens may be required for a single job. Each color of ink must usually
be stabilized by partial drying or curing before applying the next color. This is to ensure
that different colors of inks do not bleed into each other. In textile printing, however, wet-
on-wet printing is a common practice. Special low-bleed inks are used to eliminate the need
for drying or curing before applying the next color. Multi-color printing should not be
confused with four color process printing, which involves blending four colors of special
process printing inks in various thicknesses to create a full multi-color image. Only cyan,
magenta, yellow, and black process inks are used. In four color process printing, the
number of screens required is limited to four.
Both multi-color printing and four color process printing are used in the screen
printing industry.
Ink3
Ink systems are typically composed of three components: pigments, resins, and
solvents.
Pigments lend color to the ink. Colored (non-black) pigments have traditionally
contained heavy metals such as barium, cadmium, chromium, or lead, which are harmful to
3Air and Waste Management Association. Air Pollution Engineering Manual. 1992.
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the environment and to human health. However, recent technological advances have
significantly reduced the amount of heavy metals contained in many ink systems. Resins are
solids that hold the pigments together and bind them to the substrate. Solvents are needed in
some inks to dissolve the resins and pigments so that they are in a fluid state and can be
applied smoothly and evenly to the substrate.
Inks can be classified into four categories: solvent-based inks, water-based inks, UV
curable inks, and plastisol inks.
Conventional solvent-based inks are still used widely within the screen printing
industry and contain organic solvents that dissolve the resins and pigments. After printing,
the solvents must be evaporated out of the ink by a heat drying unit. Drying of solvent-
based inks releases volatile organic compounds (VOCs) to the atmosphere and can be a
primary source of ah- pollution hi a screen printing facility. The amount of VOCs emitted
depends on the amount and type of solvents contained hi the ink.
Several innovative ink systems have evolved hi response to the need for
environmentally friendly products. Use of these alternatives to conventional solvent-based
ink systems have the potential of eliminating or greatly reducing VOC emissions during the
ink drying process. These alternatives are (1) water-based inks, (2) UV curable inks, and (3)
plastisol inks.
Water-based inks use water as all or part of their solvent component. Similar to
solvent-based inks, these ink systems contain organic pigments, resins, and additives. Water-
based ink systems require the used of water-soluble resins and contain up to 65 to 70 percent
solids. Typically, water-based inks are used hi both textile and graphic applications and have
lower VOC concentrations than conventional solvent-based ink systems. Water-based inks
should not be confused with water-reducible inks, which contain as little as 10 percent water.
These inks can be thinned with water but still may use solvents as the primary resin
dissolving agent. Drying of water-reducible inks may still release considerable amounts of
VOCs to the atmosphere.
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UV curable inks consisting of pigments, monomers, oligomers, additives and
modifiers are another type of ink system. They have a solids content of nearly 100 percent
(i.e., they contain neither solvents nor water to dissolve the resins) and are cured by
exposure to ultraviolet light. Although converting a facility to accommodate their use incurs
capital expenses for installation of curing equipment, UV inks have several advantages that
make them a promising technology:
They do not dry when exposed to air and therefore are stable both in storage
and on the stencil. Clogging of dried ink on the stencil ceases to be a
problem, which eliminates the need to clean the screen during the printing run.
Curing of UV inks is nearly instant. This makes them particularly appropriate
for high speed operations where conservation of drying space can be a
significant advantage.
Curing of UV inks consumes considerably less energy than heat drying
processes.
Since UV inks contain essentially no solvents, VOC emissions are not a
significant concern.
UV inks are non-flammable.
Further development and increased use of UV inks will likely lead to improved
production efficiency as well as improved waste minimization.
Plastisol inks also contain nearly 100 percent solids and release very low levels of
VOCs. They are composed of two components—poly vinyl chloride (PVC) resins and a
plasticizer—that fuse together when heated to 160°C (320°F) hi a heat drying unit. Plastisol
inks only adhere to porous surfaces and are used primarily hi the textile printing sector.
Drying and Curing Units
Most types of inks must be dried after printing. Drying typically takes place hi either
a flash-curing unit or hi a conveyer dryer. A flash-curing unit, also known as a spot-curing
unit, contains an infrared heater that heats only the substrate and not the air around it.
Curing can often be achieved in only a few seconds with a flash-curing unit. Flash-curing
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units are typically used for plastisol inks. A conveyer dryer contains the heat inside a tunnel
through which the substrate is moved on a conveyer system. The ink is dried or cured
within the tunnel. Conveyor dryers can be either gas or electric powered and are generally
used for solvent-based and water-based ink systems.
Substrates printed with UV inks cannot be cured with conventional drying units and
must be cured in a UV curing unit instead.
Major wastes generated during printing operations are ink residues, cleaning solvents,
substrate misprints from the makeready batch, masking tape, and shop towels. The use of
spray adhesives to affix textiles to platens may also generate used aerosol cans. Many of
these wastes will contain hazardous compounds that must be disposed of properly.
2.6 Finishing (Postpress)
Finishing refers to the final handling and packaging of the product prior to delivery to
the client. The complexity of the finishing process depends greatly on the type of product
that has been printed. Screen-printed T-shirts, for example may require little or no finishing.
Plastic dashboard parts or electronic printed circuit boards, on the other hand, may require
die cutting, knife cutting, and various assembly processes to create the finished product.
2.7 Screen Reclamation (Postpress)
Due to the high price of quality fabrics, screens are cleaned after the production run
hi order to reclaim them for reuse. The screen reclamation process is of particular interest
to the inspector. It is a primary source of air emissions and hazardous wastes hi a screen
printing facility, as it involves the use of solvent-based cleaning agents that contain highly
volatile organic compounds and toxic components. It is also a common practice at many
facilities to allow waste cleaning solvents to drain directly into the sewer without proper
16
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pretreatment.4 The traditional process of screen reclamation consists of applying chemicals
in sequence that remove the ink residue, the emulsion, and any haze or ghost images that
may remain. A wide variety of chemicals can be used to reclaim screens, including many
hydrocarbon solvents, caustics, and oxidizers.
Ink Removal
The first step in screen reclamation is to remove the residual ink from the screen after
a printing run. This is generally done press side. Most of the ink can be removed by
"carding," or scraping it, from the screen. If possible, the carded ink is returned to the ink
container for reuse. Any remaining residual ink must be removed by the application of an
ink remover formula. Typically, ink remover is sprayed onto the screen with a small, non-
aerosol pump bottle, and rags are used to remove the ink residue. Lacquer thinner, which is
composed of methyl ethyl ketone, petroleum distillates, toluene, acetate, and methane, is one
common formulation used for ink remover. Some other chemicals used in ink remover
formulas are listed in Table 2. Chronic dermal or inhalation exposure to many of these
organic chemicals may present human health risks.
Major wastes generated hi the ink removal process include shop towels and VOC
emissions.
Emulsion Removal
To remove the emulsion, the screen is usually moved to the screen reclamation area.
The emulsion is removed by application of an emulsion remover formula. Emulsion remover
is applied with a brush and worked into the screen to loosen the emulsion. The screen is
then rinsed in a washout booth with water, generally at 1,000 psi. Emulsion removers are
typically water-based solutions containing a strong oxidizer such as hypochlorite or periodate.
These chemicals do not present a significant inhalation risk but do pose a risk of skin and eye
irritation and tissue damage, if adequate protective measures are not taken. Wastewater
discharges are the major issue associated with the emulsion removal process.
4U.S. EPA. Cleaner Technologies Substitutes Assessment (Draft) - Industry: Screen
Printing. 1994.
17
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Table 2. Traditional Screen Reclamation Chemicals
(Adapted from Cleaner Technologies Substitutes Assessment (Draft)—
Industry: Screen Printing, 1994.)
Use
Chemical
Estimated Market
Ink Remover
Lacquer Thinner
Xylene
Mineral Spirits
Acetone
40
20
20
20
Emulsion Remover
Sodium meta periodate
Bleach (Sodium hypochlorite)
Periodic acid
Sodium bisulfate
80
10
5
5
Haze Remover
Sodium hydroxide
Potassium hydroxide
Mixture of xylene, acetone, mineral
spirits, and cyclohexanone
Bleach (Sodium hypochlorite)
Mixture of glycol ethers and
N-methylpyrrolidone
Mixture of d-limonene and sodium
hydroxide
25
25
20
10
10
10
Haze Removal
After the ink and emulsion have been removed, a residual haze, or "ghost image,"
may remain in the image area of the screen. This is more likely to occur if dark solvent-
based inks are used, or if the screen is not reclaimed promptly after the printing run. For
certain printing applications, such ghost images are unacceptable, and they must be
chemically removed before the screen can be reused. A strong base, such as sodium
hydroxide (NaOH), is often used a haze remover. Other common chemicals used in haze
remover formulas are listed hi Table 2. The use of strong bases or strong oxidizers poses a
risk of skin and eye irritation or tissue damage, while the use of organic solvents typically
presents long-term health risks stemming from chronic dermal or inhalation exposure.
18
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Alternative Screen Reclamation Chemicals
In an effort to minimize the human health and environmental risks associated with the
use of many traditional screen reclamation chemicals, manufacturers are developing new
products which include various alternative chemicals. These alternative chemicals can be
less hazardous to the environment and to facility employees. One manufacturer, for
example, has developed an effective ink remover mixture consisting of diethylene glycol
series ethers, tripropylene glycol methyl ether, N-methylpyrrolidone, and ethoxylated
nonylphenol.5 An analysis showed that this alternative formula presents considerably lower
health risks due to inhalation exposure than either lacquer thinner or acetone.
Practical evaluation of screen reclamation chemicals must of course take into account
factors such as cost, usage required, and effectiveness, as well as environmental and health
hazards. The EPA publication Cleaner Technologies Substitutes Assessment (Draft) -
Industry: Screen Printing (CTSA) is a repository of comparative information on a wide
variety of traditional and alternative chemicals used hi screen reclamation. It includes
background information on human health and environmental health hazards of 83 chemical
substances, as well as material costs and performance evaluations of various types of
formulations and reclamation methods based on testing conducted at screen printing facilities.
Innovative Technologies in Screen Reclamation
A number of methods and technologies have been successfully applied to the screen
reclamation process hi an effort to reduce or eliminate the amount of hazardous chemicals
that must be used. These technologies include high pressure water blasters, solvent recycling
systems, and automatic screen washers. Other technologies are also under development.
Such pollution prevention alternatives may be especially appropriate in larger screen printing
facilities, where the initial capital investment for new equipment can be offset by larger
5U.S. EPA. Cleaner Technologies Substitutes Assessment (Draft) - Industry: Screen
Printing. 1994.
19
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savings in labor or chemical costs. In smaller facilities, the implementation of technologies
involving a large capital investment may be more difficult.
• High Pressure Water Blasters. High pressure water blasters that deliver
streams of water at up to 3,000 psi have been found to be effective,
particularly for ink and emulsion removal. They can be used in conjunction
with cleaning solvents to reduce the amounts of chemicals that need to be
used.
• Solvent Recycling. Solvents used in the cleaning process can be recycled in-
plant and reused. The recycling process usually consists of filtration followed
by distillation and is most often used to recover used ink remover. Filtration
removes insoluble particulates such as the solids found in ink. Distillation is a
process that vaporizes the solvent and leaves the soluble impurities, such as
ink pigments, as a residue in the bottom of a still kettle. The vaporized
solvent is passed through a matrix of refrigerated coils and is condensed back
to liquid form, purified, and ready for reuse. Solvent recyclhlg can drastically
reduce the amount of chemicals that are needed in the screen reclamation
process. When the increasing cost of hazardous waste disposal is taken into
account, the cost of the equipment for recyclhlg can be paid back in as little as
a few months.
• Automatic Screen Washers. Fully enclosed automatic screen washers can
prevent the release of solvent-based cleaners to the atmosphere during the
cleaning process. They are commercially available as ink removers only, or
as consolidated units that perform ink removal, emulsion removal, and haze
removal in a single unit. Some units include built-in solvent recovery
equipment.
• Additional Emerging Technologies. Several other environmentally friendly
technologies have been identified by EPA's Design for the Environment
program as potentially suitable for use in the screen reclamation process.
These include:
Baking soda solution sprays, which have demonstrated limited success
hi the removal of some types of inks
Dry media blasting with small particles of wheat starch or baking soda
to remove ink and emulsion
Pulse light energy technology, which exposes screens to intense
energy sources in order to vaporize coatings off the fabric
20
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Stripping technologies, in which heat or cryogenic methods are used to
loosen coatings, which are subsequently removed by sanding
Stencil/emulsion chemistry, in which the emulsion can be softened by
application of an enzyme or gelatin film and then removed with a warm
water spray.
These technologies have thus far not been successfully field tested in the
screen printing industry, but further research may increase their potential as
waste minimization continues to grow in importance.
21
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CHAPTERS
ASSESSMENT PROTOCOL
The primary purpose of the multimedia assessment protocol for screen printing
facilities is to determine compliance with regulations that apply to air emissions, hazardous
wastes, industrial wastewater, and the use of toxic substances associated with screen printing
processes. Determination of compliance with any regulations that are not specifically
associated with the screen printing process (e.g., the TSCA regulations on PCBs) is not a
part of this assessment protocol. The assessment protocol also focuses on encouraging
pollution prevention and innovative technology by identifying potential pollution prevention
and innovative technology opportunities that could move the facility beyond compliance to
overall improved environmental quality.
The multimedia assessment will utilize a process-based approach hi which the
inspector identifies noncompliance with any applicable media-specific or program-specific
regulation (air, water, solid waste) as well as pollution prevention and innovative technology
opportunities as part of the assessment of individual printing process. The assessment
protocol serves as a reference for the conduct of these assessments and includes procedures,
an assessment checklist (Appendix A), and an example assessment report (Appendix B). It
addresses prepress, press, and postpress operations for screen printing facilities.
The following activities are part of the multimedia compliance assessment protocol:
• Pre-assessment preparation
• On-site activities
Opening conference/discussion
Facility walk-through
Materials storage areas
Process areas
Waste management areas
Records/permits/documentation review
Closing conference/discussion
22
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• Preparation of assessment report
• Follow-up activities.
Each of these activities is briefly described in the assessment procedures discussed below.
During the assessment, the inspector should generally follow procedures outlined in the EPA
Basic Inspector's Training Manual.
3.1 Pre-Assessment Preparation
The inspector should review any existing information on the facility, including any
previous noncompliance problems, and determine whether the facility is in a non-attainment
area. Using the available information, he/she should complete Section I (General Facility
Information) of the Assessment Checklist, which covers general aspects of the regulatory
programs to be covered during this assessment (i.e., air, hazardous wastes, wastewater, and
use and releases of toxic substances). This information Can then be verified during the
assessment.
Prior to an assessment, the inspector should become familiar with lists such as (1) the
list of EPCRA extremely hazardous substances and their threshold planning quantities,
(2) the list of CERCLA hazardous substances and their Superfund reportable quantities, and
(3) the EPCRA list of toxic chemicals. Because these lists should also be available for
reference (if necessary) during an assessment, the inspector should carry a copy to the
facility at the time of the assessment.
3.2 On-Site Activities
Opening Conference/Discussion
During the opening conference/discussion, it is important that the inspector point out
that, hi addition to the more traditional objective of compliance evaluation, the assessment
focuses on providing compliance assistance to the facility and identifying potential pollution
prevention and innovative technology opportunities. Thus, assessment questions will address
23
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raw materials used, housekeeping procedures, and process modifications, as well as wastes
generated.
The inspector should verify the information in Section I (General Facility Information)
of the checklist and obtain any missing information. These questions are intended to obtain
an overall general evaluation of the regulations that apply to the facility, including whether
the facility currently has any permits. In addition, the printing processes at the facility
should be discussed, and a schematic prepared.
Walk-through of Facility
The Assessment Checklist is designed to walk-through the facility in a process-
oriented manner, addressing these activities:
• General housekeeping (including raw materials information)
• Image processing
• Stencil and screen preparation
• Printing
• Finishing
• Cleaning/screen reclamation
• Waste handling and management.
For each of these areas, applicable media-specific compliance questions and pollution
prevention, innovative technology, and recycling questions are included in the checklist.
General Housekeeping/Materials Storage. General housekeeping/materials
storage is a separate section of the checklist, although evaluation of these
activities should be ongoing throughout the assessment of the facility.
Specifically, the inspector should be observing operation and maintenance and
housekeeping throughout the facility walk-through in the storage areas, process
areas, and waste management areas. The walk-through of the facility should
begin at the receiving area and storage area for raw materials.
24
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Process Areas (Image Processing, Stencil and Screen Preparation,
Printing, Finishing, Cleaning/Screen Reclamation)
For each process or activity listed in the checklist, the inspector should verity
the following (using the checklist questions):
Description
Types and amounts of materials used
Types and amounts of wastes generated
General condition.
The checklist contains notes for the inspector regarding compliance issues with
respect to individual wastes.
For each type of waste generated by the process or activity, the inspector
should inquire about general or specific pollution prevention techniques and
innovative technology as presented in the checklist.
When assessing the process or activity areas, the inspector should document
any evidence of noncompliance that presents an imminent threat to human
health or the environment (e.g., leaks or spills of hazardous materials).
He/she should take immediate action to notify (1) the facility of the situation
and (2) the appropriate program office for follow-up action.
The checklist is meant only as a guide for questions, and the inspector should
ask any other questions to obtain additional information or clarify answers.
The inspector should note any transfer of wastes from one media to another
resulting from process operations.
Waste Handling and Management. The waste handling and management
section of the checklist is organized by type of waste being managed and
includes wastewater, air emissions, and hazardous wastes. This part of the
assessment will generally involve hazardous wastes storage containers,
wastewater treatment equipment, and air pollution control equipment.
However, silver recovery units, may be assessed as part of image processing,
depending on where the silver recovery unit(s) are located in the facility.
For the waste handling and management areas, the inspector should verify the
following (using the appropriate checklist questions):
Aur and wastewater:
Any existing permits and permit requirements
Type of treatment process
Condition of treatment equipment
Any noncompliance.
25
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Hazardous wastes:
Any existing permit (if TSD facility)
Condition of storage containers and storage area
Length of storage
Waste transportation.
Evaluation of these areas will also involve review of the facility records. For
example, if a facility has a wastewater permit, the inspector should review the
permit for selected requirements (e.g., limited parameters and self-monitoring
frequency) and then assess compliance with these requirements. All violations
should be documented.
The inspector should identify any media transfer of waste streams resulting
from pollution control/management practices (e.g.? generation of sludges from
wastewater treatment or generation of scrubber water from air pollution
control equipment).
Closing Conference/Discussion
As part of the closing conference/discussion, the inspector should do the following:
Convey the results of the assessment to the facility including all obvious
violations noted. However, inspectors should refrain from discussing
monetary penalty amounts, or whether penalties will be assessed for any
violations noted. Inspectors should also make the facility representative
aware that any decision with regard to a particular violation is subject to
confirmation after evaluation of the inspection findings by the appropriate
EPA program offices.
Clarify information obtained and ask any outstanding questions
Discuss in general potential pollution prevention and innovative technology
opportunities
Distribute general or printing-specific compliance assistance literature
Distribute general or printing-specific pollution prevention or innovative
technology literature
Distribute list of selected references (Appendix G)
Provide contacts at appropriate agencies that give compliance or technical
assistance (e.g., hotlines, technical assistance offices).
26
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The inspector should communicate to the facility that all results are preliminary until
follow-up review is completed.
3.3 Preparation of Assessment Report
After the assessment, the inspector should complete the assessment report form in
Appendix B. This form contains sections for results of both compliance assessment and
identification of pollution prevention and innovative technology opportunities.
Compliance Assessment Sections
The inspector should note any actual and potential violations identified during the
assessment.
Pollution Prevention Sections
The inspector should at a minimum provide a list of opportunities identified based on
the checklist questions. However, the checklist questions do not cover the full range of
potential opportunities for printing processes. If the inspector has additional time and the
appropriate references (such as those listed in Appendix C), he/she can identify other
potential opportunities that can be listed in the assessment report.
3.4 Follow-Up Activities
After the assessment, the inspector will be responsible for recommending what
follow-up actions should be taken. At a minimum, the inspector should provide a report to
the facility (example report form shown in Appendix B) that contains a compliance
assessment (with list of actual or potential violations) and a list of pollution prevention
opportunities (including innovative technology). Additional potential follow-up actions to be
taken include the following:
• Referral to specific program office for comprehensive follow-up inspection
• Referral to technical assistance office for follow-up assistance
27
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• Follow-up inspection to determine if facility has implemented pollution
prevention techniques.
After conferring with his/her supervisor, the inspector may take one or more of these
actions as per State policy depending on the particular findings of the assessment. In some
States there are special programs targeted at printing facilities. For example, the Washington
Department of Ecology has a program called Snapshots hi which inspectors provide
compliance assistance during visits to printing facilities and also provide the facility with a
summary report containing actions that it should undertake. The State of Washington is
planning follow-up inspections to determine if the facilities have completed these actions.
In some situations the inspector may decide that it is appropriate to refer the facility
to a media-specific program office because violations that could potentially pose a significant
risk to human health or the environment were found during the assessment. In any case, the
appropriate follow-up actions should be determined in coordination with the inspector's
supervisor and applicable enforcement policies.
28
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APPENDIX A
MULTIMEDIA COMPLIANCE/POLLUTION PREVENTION
ASSESSMENT CHECKLIST FOR SCREEN PRINTING FACILITIES
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MULTIMEDIA COMPLIANCE/POLLUTION PREVENTION ASSESSMENT
CHECKLIST FOR SCREEN PRINTING FACILITIES
Date and Time of Assessment:
Facility Name and Address:
Faculty Contact:
(Name, title, and phone)
Inspector (s):
Name
Title/Affiliation
Phone Number
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TABLE OF CONTENTS
I. GENERAL FACILITY INFORMATION A-l
A. General Facility Operations A-l
B. Wastewater A-5
C. Air '.'.'.'.'.'.'.'.'.'.'.'.'. A-6
D. Emergency Planning and Community Right-to-Know A-8
E. EPCRA Section 313 - Toxic Release Inventory A-9
F. Hazardous Wastes A-10
G. Toxic Substances Control A-12
II. PROCESS EVALUATION A-12
A. General Housekeeping/Materials Storage A-12
B. Image Processing A-15
a. General A-15
b. Process Solutions A-16
c. Silver Recovery A-17
d. Used Film A-18
e. Innovative Technology A-18
C. Stencil and Screen Preparation A-19
a. General A-19
b. Waste Solutions A-20
D. Printing A-20
a. General A-20
b. Waste Ink and Empty Ink Containers A-21
c. Substrate Wastes A-23
E. Finishing . A-23
F. Cleaning/Screen Reclamation A-24
a. General A-24
b. Waste Solutions A-25
c. Shop Towels A-27
d. Innovative Technology A-28
III. WASTE HANDLING AND MANAGEMENT A-30
A. Wastewater Management A-30
B. Hazardous Wastes Management A-32
c- Air '.'.'.'.'.'. A-35
111
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BACT
CERCLA
CESQG
EHS
EPCRA
ESR
HAP
IPA
LAER
LEPC
LQG
MSDS
NPDES
NSR
P2
POTW
PSD
PTE
RACT
RCRA
SERC
SQG
VOC
WWTP
ACRONYMS
best available control technology
Comprehensive Environmental Response, Compensation, and Liability Act
conditionally exempt small
quantity generator
extremely hazardous substance
Emergency Planning and Community Right-to-Know Act
electrolytic silver recovery
hazardous air pollutant
isopropyl alcohol
lowest achievable emission
Local Emergency Planning
large quantity generator
material safety data sheet
rate
Committee
National Pollutant Discharge Elimination System
new source review
pollution prevention
publicly owned treatment works
prevention of significant deterioration
permanent total enclosure
reasonably available control technology
Resource Conservation and
State Emergency Response
small quantity generator
volatile organic compound
wastewater treatment plant
Recovery Act
Commission
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GLOSSARY
Best Available Control Technology (BACT)
Technology required pursuant to Part 165 on new major sources and major modifications subject
to prevention of significant deterioration (PSD) requirements, which reflect best controls in use
taking into account costs and other non-air-quality factors.
Lowest Achievable Emission Rate (LAER)
Degree of control required pursuant to Part 173 on new major sources and major modifications in
nonattainment areas; technology must be best in use or most stringent in any State
Implementation Plan.
Major Source
Stationary source in an ozone transport region that emits or has the potential to emit at least 50
tons per year of volatile organic compounds (VOCs).
New Source Review (NSR)
Program for pre-construction review of new major sources and major modifications under
prevention of significant deterioration (PSD) and nonattainment requirements.
Nonattainment Area Requirements
Program established pursuant to Part D of Title I requiring controls necessary to attain National
Ambient Air Quality Standards (NAAQSs) in areas currently not meeting them.
Prevention of Significant Deterioration (PSD)
Program established under Part C of Title I to preserve air quality in areas already meeting
National Ambient Air Quality Standards (NAAQSs).
Reasonably Available Control Technology (RACT)
Technology required pursuant to Part 172 to be installed on existing major sources in
nonattainment areas; reflects controls EPA has identified in control technique guidelines (CTGs)
or other guidance.
VI
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Multimedia Compliance/Pollution Prevention Assessment Checklist
GENERAL FACILITY DEFORMATION
A. General Facility Operations
(1) When did the facility begin operations?
(2) Have there been previous printing operations at this location?
(3) What are the facility's hours of operation?
(4) Describe the printing system.
Yes
Complete schematic on page A-2 with raw materials input and wastes generated for each
process/activity. If possible, obtain a copy of a schematic or process diagram from the
facility.
Complete Table 1 (pages A-3 and A-4) by listing wastes generated by process/activity,
quantity generated, disposal method, and whether the waste is hazardous or nonhazardous.
A-l
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I. GENERAL FACILITY INFORMATION (Continued)
A. General Facility Operations (Continued)
Schematic of Printing Operations (Example Diagram Included)
Raw Materials Wastes Generated
Image
Processing
Stencil and Screen
Preparation
Printing
Finishing
Final Product
Screen Reclamation
Housekeeping
A-2
-------
Multimedia Compliance/Pollution Prevention Assessment Checklist
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A-4
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I, GENERAL FACILITY INFOBMATION (Continued)
A. General Facility Operations (Continued)
(5) Has a pollution prevention or waste minimization plan been developed by the
facility?
If yes, under which programs?
Yes
No
Yes
(6) Has the facility evaluated which wastes are probable candidates for reductions
through pollution prevention activities (e.g., has the facility identified or
implemented any process chemical changes to reduce air emissions or
hazardous waste generation)?
If yes, list the wastes and describe pollution prevention activities currently being undertaken.
(7) What type of training activities are conducted at the facility?
(8) Have employees been trained in the fundamentals of pollution prevention?
Yes
No
B. Wastewater
(1) Does the facility discharge wastewater into:
Surface Water? j^J Receiving Stream
NPDES Permit No.
Municipal Sewer? |_J Name of WWTP
Permit No. (if applicable)
Subsurface
System?
A-5
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I, GENERAL FACILITY INFORMATION (Continued)
B. Wastewater (Continued)
(2) In the following table, indicate type of wastewater discharged, disposal method, and volume:
Wastewater
Surface
Water
Municipal
Sewer
Disposal
Subsurface
System
Other
Sanitary
Process(es)
Noncontact Cooling
Storm Water
Other
Total
Notes to Inspector:
If the facility does not know the volume of its sanitary waste discharge, it can be estimated by
multiplying the number of employees by the residential equivalent units estimate of '25-35 gallons per
day per worker.
Storm water discharges only apply to outdoor, exposed industrial areas. Industrial areas are d
as areas where material handling equipment or activities, raw materials, intermediate products, final
products, waste materials, by-products, or industrial machinery are exposed to storm water.
C. Air
(1) Is the facility located hi an area designated as nonattainment for the National
Ambient Air Quality Standard for Ozone?
(2) Is the facility designated as a major source of:
« VOCs?
• NOX?
• Hazardous Air Pollutants (HAPs)?
Yes
No
Yes
No
A-6
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Multimedia Compliance/Pollution Prevention Assessment Checklist
1. GENERAL FACILITY INFORMATION (Continued)
C. Air (Continued)
(3) If yes, is the facility subject to applicable Reasonably Available Control
Technology (RACT) requirements?
Yes
(4) Indicate types and estimated amounts of air emissions (e.g., VOCs) from various sources
Type of Emissions
(e,g., VOCs)
Source
(e,g., Cleaning Tank)
Amount
Notes to Inspector:
The mass balance method can be used to estimate VOC emissions. An example of a mass balance to
calculate VOC emissions is presented bel&w:
Example: A printer's chemical .usage for one year is ink (10,000 Ibs, 15% VOC content) and ink
remover (1,000 gallons, $0% VOC and specific gravity 0.7)+ 100 Ibs of ink are disposed of in waste
shipments.
First, determine how many pounds of each chemical are used.
ink = 10,000 Ibs
ink remover ~ 1,000gallons x(0,7x 8.34 Ibs/gal) = 5,838 Ibs
Next, determinethe annual amount of VOCs ttsedby multiplying the pounds used by the VOC fraction.
ink = 10,000 Ibs xO.15 = 1,500 Ibs
ink remover = 5,55* Ibs x 0.5 = 2,919 Ibs
Emissions of VOCs can now be estimated by subtracting the disposed amount (or the amount remaining
with the product) from the amount used,
discarded ink = 100 Ibs x 0.15 = 15 Ibs
1,500 Ibs (from second step) - 15 Ibs - 1,485 Ibs
ink remover disposed of in
cleaning cloths = 500 Ibs
2,919 {from second step) - (500 Ibs x 0.5) = 2,669 Ibs
Total VOC emissions are 1,485 Ibs (ink) + 2,669 (ink remover) - 4,154 Ibs
A-7
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I, GENERAL FACILITY INFORMATION (Continued)
C. Air (Continued)
(5) Was equipment installed under New Source Review requirements?
Yes
No
If yes, to which of the following is the equipment subject? Check the one that applies.
Major source best available control technology (BACT) requirements under prevention
of significant deterioration (PSD)
Lowest achievable emission rate (LAER) requirements for nonattainment areas
Minor source State or local new source review (NSR) requirements
(6) Does the facility have a permit?
Permit ID
Yes
If yes, does the permit cover any of the following activities? Check any that apply.
Construction/operation of presses, control devices, distillation units, and proofing
and/or binding equipment
Operation of existing presses, control devices, distillation units, and/or proofing and
binding equipment
Modification of existing equipment.or changing materials (e.g., inks, fountain
solutions, cleaning solvents, etc.)
D. Emergency Planning and Community Right-To-Know
(1) Does the facility have on-site any of the Extremely Hazardous Substances (EHS)
in excess of the established threshold planning quantities?
If yes, list substances.
Yes
No
(2) If hazardous chemicals are present in excess of 10,000 Ibs., have the
material safety data sheets (MSDS) (or a list of chemicals) and chemical
inventory forms been submitted to State and local emergency planning
authorities and fire departments?
N/A
Yes
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I. GENERAL FACILITY INFORMATION (Continued)
D. Emergency Planning and Community Right-To-Know (Continued)
N/A
(3) Were the State Emergency Response Commission (SERC) and Local
Emergency Planning Committee (LEPC) notified of their presence for
local planning purposes?
(4) Has the facility released an extremely hazardous substance (EHS) or a CERCLA
hazardous substance in excess of the Superfund reportable quantity?
If yes, was notification of the release provided?
To whom?
Was notification oral or written?
Yes
No
Yes
No
Was oral notification followed up by written notification?
(5) Does the facility have Material Safety Data Sheets (MSDS) readily available
for all hazardous chemicals used? (OSHA)
Yes
No
Yes
No
E. EPCRA Section 313 - Toxic Release Inventory
(1) Does the facility have ten*or more full-time employees?
(2) Did the facility use more than 10,000 Ibs. of at least one toxic chemical
during a previous calendar year?
If yes, did the facility file a Section 313 Toxic Chemical Release Inventory
Form R for the chemicals?
Yes
No
Yes
No
N/A
Yes
No
A-9
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I. GENERAL FACILITY INFORMATION (Continued)
F. Hazardous Wastes
(1) Does the facility generate hazardous wastes from printing activities?
(2) Does the facility have an EPA ID No.?
EPA ID No.:
Yes
No
Yes
(3) Is the facility's waste determination method (i.e., to determine whether
a waste is hazardous or nonhazardous) adequate?
(a) Does the facility determine if its waste is excluded from regulation under
Part 261.4(b) (i.e., solid wastes which are not hazardous wastes, such as
household waste)?
(b) If no, does the facility determine if the waste is listed hi Part 261,
Subpart D (examples of listed wastes typically found hi the printing
industry include tetrachloroethylene, methylene chloride, xylene, and
acetone)?
If yes, does the facility determine if the waste has been excluded from
the lists in Subpart D or Part 261.3 in accordance with 260.20 or
260.22 (which allows petitions to amend Part 261 to exclude a waste
produced at a particular facility)?
If no, does the facility determine if the waste exhibits any of the
characteristics specified in Part 261, Subpart C flfor example,
characteristics of ignitability, corrosivity, reactivity, and EP toxicity)?
(4) Is the facility a
Large quantity generator?
Small quantity generator?
Conditionally exempt small quantity (CESQG) generator?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
1. GENERAL FACILITY IMPGKMAMQN (Continued)
F. Hazardous Wastes (Continued)
Notes to Inspector:
CSieck amounts in Table 1 to determine appropriate classification for facility.
Large quantity generator fLQ&) generates 1,000kg {2,200 BK) of hazardous waste (HW) or more per
month. The waste must be shipped in 90 days and there is no limit to the amount that may be
accumulated.
Smallquantity generator (SQG) generates between 100kg (220 tbs) and 1,000kg &2QQttte) nonacute
HWin a calendar month. The waste must be shipped in 180 days and is limited to accumulating no
more than &QOQ kg (13,200 Ibs) HWon-site.
A conditionally exempt small quantity generator (CESQG) generates nomorethan 100kg {220lbs)ffW
in a calendar month and accumulates less than 1,000kg (2,200 Ibs} on-sitei OR, generates less than
1 kg (2.2 Ibs) acute HWin a calendar month and accumulates less than 100 kg (220 Ibs) acute
(5) Excluding CESQGs, are the hazardous wastes at the facility consistent
with generator notification records (i.e., has the facility notified the State
or EPA of all generated wastes)?
(6) What are the hazardous wastes management practices? Check all that apply.
On-site: Satellite accumulation
Container storage
Tank storage
Treatment
Disposal
Other
N/A
Yes
No
D
D
D
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Multimedia Compliance/Pollution Prevention Assessment Checklist
I.
F.
(7)
(8)
G.
(1)
II.
A.
(1)
(2)
GENERAL FACILITY INFORMATION (Continued)
Hazardous Wastes (Continued)
If the facility ships hazardous wastes off-site, is a manifest system used?
Does the facility generate wastes that are restricted from land disposal
(i.e., liquid hazardous wastes having a pH < 2.0; liquid hazardous wastes
containing halogenated organic compounds at > 1,000 mg/L)?
If yes, does the facility comply with Part 268 for land disposal of restricted
wastes?
Yes
No
Yes
No
Yes
No
Toxic Substances Control
Does the facility import any chemical substances (e.g., ink)?
N/A
If yes, has the facility completed the appropriate certification statement?
Yes
No
Yes
No
PROCESS EVALUATION
General Housekeeping/Materials Storage
Note to Inspector:
Check Table 1 (i.e., Summary of Wastes Generated, Quantify, and Disposal methods) to verify wastes
generated as you complete this section of the checklist.
Typical "wastes generated include: shop towels, used solvent and ink containers, and stir sticks.
Note any potential or actual problems regarding housekeeping and storage (e.g., z
hazardous and nonhazardous solid wastes, and wastewater).
Is the shop clean and orderly to prevent accidents and spills? '
dr emissions,
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II. PROCESS EVALUATION (Contoured)
A. General Housekeeping/Materials Storage (Continued)
(3) Are chemicals kept in covered containers to minimize losses from evaporation
and spills?
(4) Does the facility use spigots and pumps when dispensing raw materials?
(5) Does the facility use funnels for transferring wastes to storage containers?
(6) Does the facility implement dry methods for cleanup whenever possible?
(7) Does the facility have a spill prevention plan?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Note to Inspector:
Some POTWs may reqwre printing facilities to develop spill prevention (or slug control) plans that
include the following:
• Description of discharge practices, including non-routine batch discharges
* Description of stored chemicals
» Procedures for immediately notifying the PCffW of slug discharges
, * Procedures to prevent adverse impacts from spills
(8) Are there any floor drains leading directly to the sewer where the solvent or ink
is stored?
Yes
No
If yes, in the event of a spill, will contaminants enter the floor drains?
N/A
Yes
No
If yes, what is the characteristic of wastewater contained in the floor drains and where do
the floor drains discharge?
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II. PROCESS EVALUATION (Continued)
A. General Housekeeping/Materials Storage (Continued)
(9) Are the amounts of chemicals stored in the process areas minimized to
encourage materials conservation?
(10) Does the facility use a "first-in first-out" policy to avoid the expiration of raw
materials?
(11) Are infrequently used materials ordered in small containers?
(12) Are frequently used materials ordered in large containers?
(13) Does the facility store products in locations that will preserve their shelf life?
Yes
Yes
No
Yes
No
Yes
No
Yes
No
(14) If materials have exceeded their shelf life, are alternative uses considered
before discarding?
(15) Does the facility purchase materials from manufacturers that will accept
returned materials if shelf life is exceeded?
N/A
Yes
N/A
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H. PROCESS EVALUATION (Continued)
B. Image Processing
a. General
Yes
(1) Is image processing done at the facility?
Note to Inspector:
Check Table 1 (i.e., Summary of Wastes Generated, Quantity, and Disposal Methods) to verify wastes
generated as you complete this section of the checklist.
Typical wastes from image processing include the following: used film, process solutions containing
photographic chemicals (fixer and developer), and silver {dissolvedpom processing film).
Typical hazardous wastes generated from image processing include: developers and fixers. Most
developers contain levels ofhydroquinone. If disposed of as on unused product it may be defined as
a hazardous waste in applicable State regulations due to the concentration of hydroqumone. If the
hydroquinane is consumed during use and does not shove up in used developer, it is not considered
hazardous. Fixers which allow silver to dissolve out dfthejifm and paper can contain up to 4fQ00j7pm
silver. Any solutions containing silver at concentrations greater than 5ppm are considered hazardous
wastes.
Jn addition, some fOTWs may have limits for silver in industrial discharges that are below $ppm* The
facility should be aware of the applicable silver limits for its discharge.
(2) Note any potential or actual problems regarding image processing with respect to air
emissions, nonhazardous and hazardous solid wastes, and wastewater.
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H,
B.
(1)
(2)
(3)
(4)
(5)
PROCESS EVALUATION (Continued)
Image Processing (Continued)
b. Process Solutions
List the chemicals/solutions and amounts used for:
Type
Developer
Fixer
Stop Bath
How are bath solutions currently monitored?
Are bath solutions changed on a set schedule?
If yes, what is the schedule?
Amount
Y*
s No
With respect to the process bath, does the facility do any of the following:
• Add ammonium thiosulfate to silver-contaminated
allowable build-up of silver?
• Prolong the potency of oxidation process baths by
air?
• Routinely monitor pH?
Does the facility use squeegees following all processin
automatic processing machines?
Y«
baths to extend the
Y«
reducing their exposure to
Y«
Y«
g solutions and washes in
Note to Inspector:
Squeegees can significantly reduce the amount of solution carried out of the bath on the film.
reduces bath changeouts and replenishment rates. Types of squeegees include wiper blades
squeegees, vacuum squeegees* wringersling squeegees, and rotary-buffer squeegees.
s No
s No
s No
* No
This
, air
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II. PROCESS EVALUATION (Continued)
B. Image Processing (Continued)
(6) Does the facility use water recirculation units to reduce water use and
wastewater generation?
(7) If the facility uses multiple rinses, is counter-current rinsing used?
Yes
N/A
Yes
No
Note to Inspector:
If no, -water recirculation units can reuse photoprocessing bath waters bat filters from water
recirculation units require disposal and may be considered hazardous wastes.
(8) Is an automatic film processor used?
Yes
No
N/A
Yes
No
If yes, is a continuous rinse used?
How often are the processor's chemical tanks cleaned out?
c. Silver Recovery
(1) Does the facility use any of the following on-site silver recovery techniques to reduce silver
concentrations in the discharge? (Check any that apply.)
Electrolytic silver recovery
Automatic recirculating silver recovery
Metallic replacement canisters
Ion exchange units
Other (specify)
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II, PROCESS EVALUATION (Continued)
B. Image Processing (Continued)
(2) Does the facility ship wastes for off-site silver recovery?
Yes
Note to Inspector:
Several on-site and off-site silver recovery methods are available.
• On-site units include the following: electrolytic stiver recovery (ESR) and metallic replacement
units. Silver removed from the ESR and the metallic cartridges and fixer solutions are hazardous
wastes and must be handled properly.
• Off-site silver recovery includes sending fixer bath solutions to a fixer recycter to recover silver and
possibly regenerate the fixer or processing off-site cartridges from an on-site metallic replacement
canister.
d. Used Film
(1) Does the facility recycle photographic film?
(2) Has the facility explored the use of silverless films?
If yes, which type? (Check any that apply.)
Yes
Yes
No
Diazo
Photopolymer
Electrostatic
Has the use of these films reduced the amount of silver contaminated fixer
or wash solutions?
e. Innovative Technology
(1) Has the facility considered installing waterless paper and film developing units
to reduce the volume of fixer waste?
Yes
Yes
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II. PROCESS EVALUATION (Continued)
B. Image Processing (Continued)
Yes
(2) Does the facility use electronic imaging?
C. Stencil and Screen Preparation
a. General
Note to Inspector:
Check Table 1 (lv<, Summary of Wastes Generated* Quantity, and Disposal Methods} to verify wastes
generated as you complete this section of the checUist.
Typical waste?from stencil and screenpreparation include thefallowng? waste emulsion, paper, spray
adhesive, and wastewater*
(1) Note any potential or actual problems regarding stencil and screen preparation with respect to
air emissions, hazardous and nonhazardous solid wastes, and wastewater.
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H, PROCESS EVALUATION (Contaraed)
C. Stencil and Screen Preparation (Continued)
(2) What type of stencils are used?
Direct coating stencil
Indirect film stencil
Capillary film stencil
Hand cut stencil
b. Waste Solutions
(1) List the emulsion materials, adhesives, and any other solutions used hi the stencil and
screen preparation and note any hazardous materials they may contain.
D. Printing
a. General
Nate to Inspector:
Check Table I (Le., Summary of Wastes Generated, Quantity, and Disposal Methods) to verify wastes
generated as you complete this section of the checklist.
Typical -wastes from printing processes include the following: waste substrates, volatile organic
compounds, waste ink, empty ink containers, and used plates.
Used printing inks can contain materials that would be considered hazardous wastes. For some
chemicals the wastes are hazardous at any concentration while for other chemicals, the wastes are
hazardous if they exceed specific regulatory limits.
Some agencies have requirements on the maximum VOC content for printing inks.
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II. PROCESS EVALUATION (Continued)
D. Printing (Continued)
(1) Note any potential or actual problems regarding printing with respect to air emissions,
hazardous and nonhazardous solid wastes, and wastewater.
b. Waste Ink and Empty Ink Containers
(1) Do any of the inks contain hazardous materials such as solvents or heavy metals
(e.g., fluorescent/bright-colored inks frequently contain higher concentrations of
heavy metals)?
List the hazardous constituents.
Yes
(2) Does the facility use any of the following less hazardous inks? (Check any that apply.)
Water-based inks
Ultraviolet curable inks
Plastisol inks
(3) Does the facility use any of the following measures to reduce cleaning? (Check any that
apply.)
Use a standard ink sequence
Run similar jobs on the same day or schedule jobs using light colored inks before
darker ones
Dedicate one press for inks containing hazardous pigments or solvents
A-21
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II, PROCESS EVALUATION (Continued)
D. Printing (Continued)
(4) Does the facility do any of the following with unused portions of ink? (Check any that
apply.)
Save for house colors
Offer customer discounts on leftover inks
Use on donated jobs
If no, what do they do with the unused inks?
(5) Does the facility do any of the following with waste inks? (Check any that apply.)
Reuse
Recycle
Return to the manufacturer
(6) Does the facility purchase ink in bulk containers that may be returned to the
supplier for refilling?
(7) Are inks removed from stir sticks with a scraper or spatula, rather than a towel?
(8) Are inks containing hazardous substances disposed of as hazardous waste?
Yes
Yes
No
Yes
No
A-22
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H, PROCESS EVALUATION (Continued)
D. Printing (Continued)
c. Substrate Wastes
(1) Is substrate use minimized by proper pre-production planning and lay-out?
(2) Are waste paper and trash sent to a recycler?
(3) What are the most common causes of misprints?
Yes
Yes
No
(4) Does the facility monitor press performance continuously to minimize bad runs
and waste?
E. Finishing
(1) What type of finishing operations are done at the facility?
Yes
No
JN0te to Inspector:
Check Table I (Le., Summary of Wastes Generated, Quantity, and Disposal methods} to verify wastes
generated as you complete this section of the checklist.
(2) Note any potential or actual problems regarding finishing operations with respect to air
emissions, nonhazardous and hazardous solid wastes, and wastewater.
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Multimedia Compliance/Pollution Prevention Assessment Checklist
EVALUATION (Continued)
F. Cleaning/Screen Reclamation
a. General
Notes to Inspector;
Check Table I (ie.t Summary of Wastes Generated, Quantity, and Disposal Methods) to verify wastes
generated as you complete this section of the checklist.
Typical wastes from cleaning/screen reclamation activities include; ink remover with residual ink,
emulsion remover, haze remover, rags or shop towels containing cleaner and ink, empty solvent
containers, and VOC emissions from cleaning solvents. All of these -wastes are potentially hazardous
•wastes, if they contain substances with F-listed chemicals.
Tear-down and repair of equipment can produce large quantities of cleaning waste as compared to
waste produced during normal operation.
(1) Does the facility reclaim screens?
Yes
No
(2) What type of other cleaning activities does the facility perform and how often are they
performed?
(3) Note any potential or actual problems regarding cleaning/screen reclamation activities with
respect to air emissions, nonhazardous and hazardous solid wastes, and wastewater.
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H. PROCESS EVALUATION (Continued)
F. Cleaning/Screen Reclamation (Continued)
b. Waste Solutions
(1) Describe the various processes used in the facility to reclaim screens and list the cleaning
solvents used in association with these processes.
Reclamation Task
Ink Removal
Emulsion Removal
Haze Removal
Other
Process Description
Cleaning Solvents Used
(2) List the types of solutions used for other cleaning purposes.
(3) Does the facility purchase screen reclamation solvents that do not contain
F-listed wastes?
Yes
No
Note to Inspector:
F-listed wastes are chemicals designated by EPA to be hazardous wastes from non-specific source, and
have an EPA hazardous waste number beginning with F. A summary of F-listed chemicals most
commonly found in screen printing wastestreams is found in Footnote I of Table I in the main text.
The compJetelist ofehemicalsandtheircorrespondinghazardons waste numbers are in§26L31 of Title
40 of the Code of Federal Regulations.
(4) Has the facility worked with its vendor to find the lowest VOC solvents that
work effectively?
(5) Has the facility tested more dilute solutions of cleaning solutions to determine
whether they would be equally effective?
Yes
No
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H. PROCESS EVALUATION (Continued)
F. Cleaning/Screen Reclamation (Continued)
(6) Does the facility have a solvent management plan to reduce solvent waste at the
facility?
(7) Are cleaning chemicals applied to the screen evenly with a low volume method,
such as an adjustable spray nozzle and a brush, rather than being hosed on?
(8) Are "catching frames" installed behind spray nozzles to collect excess cleaning
solvent for reuse?
(9) Is a scraper used to remove as much excess ink from a used screen as possible
before a chemical ink remover is applied?
(10) Are screens reclaimed promptly after the printing run to facilitate removal of
ink and emulsion, and to reduce the chance that a caustic haze remover will be
required?
(11) Has the facility attempted the application of screen degreasers and ink
degradants before the emulsion remover to avoid the use of haze remover?
(12) If haze remover is required, is it applied only to the part of the screen that is
stained?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
(13) Does the facility have solvent containers or tanks?
If yes, are solvent container lids tight fitting and in place when not in use?
Yes
No
Yes
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II, PROCESS EVALUATION (Continued)
F. Cleaning/Screen Reclamation (Continued)
(14) Are solvent tanks equipped with emission control equipment?
If yes, specify.
(15) Are spent solvents separated to facilitate recycling or proper disposal?
If so, how are they separated?
Hazardous/nonhazardous
Chlorinated/nonhazardous
Other:
(16) How are waste solvents handled? (Check any that apply.)
Discharged to drains
Captured as liquid
Absorbed with rags, shop towels, or other absorbent materials
c. Shop Towels
(1) How are shop towels handled? (Check one that applies.)
Washed on premises
Picked up by commercial laundry:
N/A
Yes
No
Yes
No
(name of laundry)
(2) Does the facility use towels as long as possible before discarding or laundering?
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
H. PROCESS EVALUATION (Continued)
F. Cleaning Screen Reclamation (Continued)
(3) Are used shop towels stored in closed, fire-resistant containers?
(4) Does the facility implement procedures to remove excess solvents or inks in the
rags so they can be cleaned by an industrial laundry?
Is the recovered solvent reused?
Yes
No
Yes
No
Yes
No
t» inspector:
A variety of approaches can be used to minimize the amount of solvents or inks in rags. These include:
» Changing cleanup procedures so that solvent levels are kept to a minimum in the rags
- Use practices mat limit the worker's ability to soak rags in solvent (plunger cans, squeeze bottles?
daily solvent allocations, directly poor solvent -waste into labeled drtaris, etc.)
» Developing a procedure to separate a majority of the ink and solvent from soaked rags (centrijagal
extractor or wringer)
d. Innovative Technology
(1) Does the facility reuse or recycle solvents?
If yes, how is it reused or recycled?
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
II. PROCESS EVALUATION (Continued)
F. Cleaning/Screen Reclamation (Continued)
(2) If solvents are recycled on-site:
Does the solvent recycling process generate cooling water?
N/A
Yes
No
What procedures are used to ensure cooling water is not contaminated from equipment leaks?
(3) Does the facility use a high-pressure water blaster in the ink removal and
emulsion removal process to reduce the amount of waste chemicals generated?
(4) Does the facility use fully enclosed automatic screen washers to reduce
atmospheric VOC emissions, conserve solvent, and protect workers from
exposure to hazardous chemicals?
(5) Has the facility tested baking soda sprays in the removal of ink and emulsion?
Yes
No
Yes
No
Yes
No
(6) Has the facility used any of the following emerging screen reclamation technologies?
Media blasting
Pulse light energy technologies
Stripping techniques
Emulsion chemistry
If yes, describe the technology and any issues associated with the use.
Yes
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Multimedia Compliance/Pollution Prevention Assessment Checklist
HI. WAStE HANDLING AND MANAGEMENT
A. Wastewater Management
(1) List the expected pollutants in the facility's wastewater discharge.
(2) Does the POTW have sewer use limits for any of these pollutants?
If yes, list the pollutants.
No
(3) Does the facility have a current wastewater discharge permit?
If no, has the facility applied for a permit?
(4) If the facility has a wastewater discharge permit, complete the following:
List the parameters limited in the facility's permit.
N/A
N/A
No
Parameter
Limit
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Multimedia Compliance/Pollution Prevention Assessment Checklist
10. WASTE HANBLINC AND MANAGEMENT (Contuaied)
A. Wastewater Management (Continued)
Is the facility in compliance with the following requirements in its permit?
Permit limits
Sampling location
Sampling frequency
Parameters analyzed
Analytical methods
Reporting
Recordkeeping
N/A
Y«s
No
If no is checked for any of the above items, describe the potential or actual noncompliance
with specific permit requirements.
(5) Describe any observable impact of the wastewater discharge. (For example, is the discharge
murky or are there any unusual odors?)
(6) Describe any wastewater treatment employed at the facility. (Note: This does not include
any recovery systems.)
(7) Is wastewater treatment sludge generated on-site?
If yes, how is it disposed?
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
III. WASTE HANDLING AND MANAGEMENT (Continued)
A. Wastewater Management (Continued)
If applicable, where does the water, removed from the sludge dewatering process, return to
the facility?
(8) For facilities that discharge to POTWs, did the facility notify the POTW if any
substances discharged by the facility would be a hazardous waste under 40 CFR
Part 261?
Yes
No
B. Hazardous Wastes Management
(1) Is hazardous waste accumulated in containers at or near the point of generation
(i.e., in the process areas)?
Yes
No
N/A
If yes, is the capacity of the containers less than 55 gallons or is the
quantity of wastes accumulated less than 55 gallons?
Is excess accumulation removed within 3 days?
(2) Does the facility have a hazardous waste storage area?
(3) Are the waste storage containers indoors or in covered areas to prevent moisture
from seeping in?
Yes
No
Yes
No
Yes
No
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
HI. WASTE HANDLING AND MANAGEMENT (Continued)
B. Hazardous Wastes Management (Continued)
(4) Are the hazardous wastes containers managed as follows? (Check all that apply.)
Containers hi good condition (no rusting, defects, or evidence of leaks)
Containers properly labeled as hazardous type of waste and start date of accumulation
Containers compatible with waste
Containers closed when not in use
Containers opened, handled, and stored hi a manner not to cause a leak
Containers storing incompatibles kept separate
Containers appropriately stored for:
90 days or less
180 days or less
270 days or less
For items not marked, please describe the problem.
(5) Is there adequate secondary containment capacity for free liquid wastes stored
in a storage area?
(6) Are any hazardous wastes shipped off-site?
If yes, does the facility use a manifest system?
Yes
No
Yes
No
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
HI. WASTE HANDLING AMD MANAGEMENT
B. Hazardous Wastes Management (Continued)
(7) Do the manifest records contain the following? Check all that apply.
Generator EPA ID number
Generator name, address, phone number
Transporter name, EPA ID number
Designate facility name, address, phone number, and EPA ID number
Alternate facility identified
Five-digit document number
DOT shipping name, hazard class, waste code, and RQ
Containers: number, type, quantity, unit wt/vol
Proper certification, including waste mmimization
Dates and signatures
(8) Have exception reports been required?
If yes, have they been submitted?
(9) Are manifest records' maintained for 3 years?
(10) If wastes are reclaimed, does facility have a copy of the contractual
agreement with reclaimer?
Yes
No
N/A
Yes
N/A
Yes
No
N/A
Yes
No
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Multimedia Compliance/Pollution Prevention Assessment Checklist
HI. WASTE HANDLING AND MANAGEMENT
B. Hazardous Wastes Management (Continued)
(11) Has the facility determined and submitted notifications of hazardous waste
restricted from land disposal?
If yes, do the notifications contain the following? (Check all that apply.)
N/A
Yes
EPA hazardous waste number (e.g., F002)
The corresponding treatment standard(s) [see 40 CFR 268.7(a)(l)(ii) for details]
The manifest number associated with the shipment of waste
Waste analysis data, where available
(12) If land disposal restricted wastes are treated on-site, does facility have
records documenting that wastes meet land disposal restriction treatment
standards?
N/A
Yes
No
C. Air
(1) Does the facility have any of the air pollution control technologies?
If yes, check any that apply.
Yes
No
Incinerator
Carbon Absorption Unit
Condenser
Ventilation Capture System
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Multimedia Compliance/Pollution Prevention Assessment Checklist
HI. WASTE HANDLING AND MANAGEMENT
C. Air (Continued)
Note to Inspector:
Air pollution control technologies include the following:
• Incinerators (including catalytic} - Incineration of exhaust gas is widely used in the printing
industry. Ojten> heat is recycled hack into the building (i.e,, feat-set offset) or process dryers.
Compliance is monitored by incineration temperature or change in temperature across the catalytic
surface.
» Carbon Absorption - Carbon beds capture exhaust VOCs which are recoveredperiodically through
a steam stripping process. Presses/fctciMesutilizingasinglesolventcan efficietafyrecoversotvent
for on-site use. This method is typically used on larger presses with hydrocarbon monitors to
confirm efficiency.
• Condensers - Refrigerated coils are used to cool exhaust gas and cause solvent to condense for
recovery. Condensers are not widely used in the graphics arts industry.
(2) Does the facility have an air permit?
If no, has the facility applied for a permit?
Yes
Yes
(3) If the facility has an air permit, is it in compliance with the following requirements in its
permit?
Emissions limits
Emissions monitoring
Analytical methods
Reporting
Recordkeeping
Other (describe):
N/A
No
(4) If no is checked for any of the above items, describe any actual or potential violations with
specific permit requirements.
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APPENDIX B
MULTIMEDIA COMPLIANCE/POLLUTION PREVENTION
ASSESSMENT REPORT FORM
FOR SCREEN PRINTING FACILITIES
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Multimedia Compliance/Pollution Prevention Assessment Report Form
FACILITY NAME AND
LOCATION:
MAILING ADDRESS:
(if different)
FACILITY CONTACT(S):
Name Title/Affiliation Phone Number
ASSESSMENT DATE:
INSPECTOR^):
Name Title/Affiliation Phone Number
REASON FOR VISIT:
AREAS VISITED:
DATE FORM COMPLETED:
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Multimedia Compliance/Pollution Prevention Assessment Report Form
I. GENERAL FACILITY DESCRIPTION
Provide a general description of the facility (e.g., building age, length of business at this
location, previous owners/operators at the site, printing capacity, brief description of
processes, brief overview of wastes generated and disposal methods used, and status of
P2 implementation efforts).
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Multimedia Compliance/Pollution Prevention Assessment Report Form
II. COMPLIANCE ASSESSMENT
Wastewater
Describe any observed or potential violations:
Referral to other program office
Air Quality .
Describe any observed or potential violations:
Referral to other program office
Emergency Planning and Community Right-to-Know Act (EPCRA)
Describe any observed or potential violations:
Referral to other program office
Hazardous Waste [Resource Conservation and Recovery Act (RCRA)]
Describe any observed or potential violations:
Referral to other program office
Toxic Substances Control
Describe any observed or potential violations:
Referral to other program office
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Multimedia Compliance/Pollution Prevention Assessment Report Form
IH. POLLUTION PREVENTION (P2) AND INNOVATIVE TECHNOLOGY
OPPORTUNITIES IDENTIFIED
List each waste at the facility with any associated P2 and innovative technology
opportunities. Use additional sheets for more information.
PROCESS - IMAGE PROCESSING
Raw Materials or Waste
Description
Pollution Prevention and Innovative Technology
Opportunities
PROCESS - STENCIL AND SCREEN PREPARATION
Raw Materials or Waste
Description
Pollution Prevention and Innovative Technology
Opportunities
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Multimedia Compliance/Pollution Prevention Assessment Report Form
in. POLLUTION PREVENTION (P2) AND INNOVATIVE TECHNOLOGY
OPPORTUNITIES IDENTIFIED (Continued)
List each waste at the facility with any associated P2 and innovative technology
opportunities. Use additional sheets for more information.
PROCESS - PRINTING
Raw Materials or Waste
Description
Pollution Prevention and Innovative Technology
Opportunities
PROCESS - FINISHING
Raw Materials or Waste
Description
Pollution Prevention and Innovative Technology
Opportunities
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Multimedia Compliance/Pollution Prevention Assessment Report Form
ffl, POLLTJTION PREVENTION (P2) AND INNOVATIVE TECHNOLOGY
OPPORTUNITIES IDENTIFIED (Continued)
PROCESS - SCREEN RECLAMATION/CLEANING
Raw Materials or Waste
Description
Pollution Prevention and Innovative Technology
Opportunities
PROCESS - OTHER
Raw Materials or Waste
Description
Pollution Prevention and Innovative Technology
Opportunities
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Multimedia Compliance/Pollution Prevention Assessment Report Form
IV. CONCLUSIONS AND RECOMMENDED FOLLOW UP
A. Compliance Violations and/or Issues [add regulatory references (i.e., 40 CFR 261.30)].
B. Potential P2 Opportunities and Innovative Technologies. (These are only suggestions
and not regulatory requirements.)
C. Follow-up Responses to Compliance Questions Asked During On-Site Assessment.
(This section should include responses to compliance questions asked during the on-site
assessment that the inspector was unable to answer.)
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APPENDIX C
ANNOTATED BIBLIOGRAPHY OF SELECTED REFERENCES
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APPENDIX C
ANNOTATED BIBLIOGRAPHY OF SELECTED REFERENCES
This is not meant to be a comprehensive list of pollution prevention resource materials
on the screen printing process. Rather, it contains a range of references that could be
used for initial review by the inspector. Many of these documents also contain
reference lists. In addition, discussion of specific pollution prevention techniques and
innovative technologies, or mention of trade names of commercial products, hi these
documents does not constitute an endorsement or recommendation for use by EPA.
Alaska Health Program. April 1991. Waste Reduction Assistance Program. Waste Reduction
Guide: Printing Business.
Manual designed to assist the printing business in identifying and implementing waste
reduction opportunities.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
Aspesi, Luigi. February 1987. UVInks: Their use in four color process screen printing using
UCR. American Ink Maker. Volume 65, No. 2.
Journal article that presents the advantages of the Under Colour Removal (UCR) system in
four color process screen printing using UV inks.
California Department of Health Sciences. May 1988. Waste Audit Study: Commercial
Printing Industry. Prepared for the Alternatives Technology Section, Substances Control
Division, California Department of Health Sciences. Sacramento, CA.
Study identifying -waste minimization techniques available to printers. Recommendations and
findings are included as well as checklists that can be used by printers to perform their own
•waste audits.
Available From: California Department of Health
Department of Toxic Substances Control
Office of Pollution Prevention Technology and Development
Document #303—Limited to existing stock
(916)324-1087
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Annotated Bibliography of Selected References
Connecticut Technical Assistance Program. August 1992. On-Site Waste Ink Recycling. The
Hartford Courant. Hartford, CT.
In-depth case study of how one large newspaper developed a waste ink recycling program.
The project addressed product quality, waste reduction, and the economic issues involved
in recycling press ink. Information on testing and comparison of virgin and recycled ink
are documented. Economic information regarding the resulting cost savings is provided.
Available From: CONNTAP
50 Columbus Blvd., 4th floor
Hartford, CT 06106
(203) 241-0777
Easton, J.R. and J.R. Provost. "Pollution Control and the Textile Printer." International Dyer,
Textile Printer, Bleacher and Finisher, Sept. 1993.
This article presents several applications of new technologies that could minimize pollution
in the textile printing industry. Methods discussed include computerized ink jet print process
as a substitute for screen printing and integration of computer systems into the color kitchen
process to reduce waste.
Hawaii Department of Health. Solid and Hazardous Waste Branch. September 1993.
Hazardous Waste Minimization News: Waste Minimization in Action - Printing Operations.
Newsletter featuring tips and ideas on reducing hazardous -wastes generated at printing
operations.
Available From: Hawaii Department of Health
Solid and Hazardous Waste Branch
919 Ala Moana Blvd., Rm. 212
Honolulu, HI 96814
(808) 586-4373
Iowa Waste Reduction Center. Undated. Eliminating the Screen Printing Photographic
Prepress: A Case Study in Pollution Prevention and Industry Readiness.
An analysis of current practices in the screen printing industry with regard to positives
generation and waste disposal options for screen printing prepress operations.
Available From: Iowa Waste Reduction Center
University of Northern Iowa
75 Biology Research Complex
Cedar Falls, IA 50614-0815
(319) 273-2079
Jones, Alan. June 1985. Container decoration: substrates and inks. Screen Printing, Vol. 75,
No. 6.
This article discusses the evolution and present state of the decoration of plastic bottles by
the screen printing process. The advantages of UV curing inks are presented.
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Annotated Bibliography of Selected References
King County (Washington) Local Hazardous Waste Management Program. Screen Print Project:
Screen Printing Process (with Flow Diagram). King County, Washington.
This brief guide describes the screen printing processes including an preparation, screen
preparation, production, clean-up activities. The materials used and the -wastes generated
at each step of the process are identified. A flow diagram is included to show a schematic
representation of the screen printing process, including the raw material inputs and waste
outputs.
Available from: Local Hazardous Waste Management Program
(King County, Washington)
(206) 689-3090
King County (Washington) Local Hazardous Waste Management Program. May 1994. Screen
Printers: Waste Management Guide. King County, Washington.
A guidebook that provides screen printers in King County with information about the best
ways to manage and dispose of aerosol cans, waste ink, shop towels, photo-processing
solutions, wastewater, and waste solvent.
Available from: Local Hazardous Waste Management Program (King County)
(206) 689-3090
Kinter, Marcia. August 1989. The Movement Towards Clean Air: What it Means for the
Screen Printer. Screen Printing, Vol. 79, No. 9.
This article presents information to educate the screen printing industry by exploring the
Clean Air Act and discussing the important principles involved. In addition, this article
aims to help the screen printer understand why the industry has been targeted to reduce its
emissions of pollutants.
New York State Department of Environmental Conservation. September 1991. Hazardous
Waste Management for Printers.
Pamphlet providing information regarding hazardous wastes, waste reduction and recycling
strategies, information available from the State of New York, and information on how to
categorize waste streams (i.e., hazardous, nonhazardous).
Available From: New York State Department of Environmental Conservation
Division of Hazardous Substance Regulation
50 Wolf Road
Albany, NY 12233-7253
(212) 637-4100
Screen Printing Association International. Undated. Government Resource Book. Screen
Printing Association International.
This document provides the screen printer with overviews of the Federal Clean Air Act, the
safely and health regulations, the Safe Drinking Water Act, the various industrial waste
operations, and the labeling of products using ozone depleting substances.
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Annotated Bibliography of Selected References
Available From: Screenprinting and Graphic Imaging Association International
10015 Main Street
Fairfax, VA 22031
(703) 385-1335
State of Montana, Department of Health and Environmental Sciences. June 1988. The Small
Quantity Generator's Handbook for Managing RCRA Wastes - Printing and Publishing.
This is a handbook developed for the printing and publishing industry to comply with RCRA
requirements. The manual also provides insight into waste management strategies for
minimizing waste quantities. Information was compiled through site visits to various
printing shops. The handbook also summarizes the RCRA regulations that apply to printers.
Available From: State of Montana
Division of Wastes
(406) 444-1430
Also available is a 1995 Updated Version: Small Business Handbook for Managing
Hazardous Wastes.
Tellus Institute. June 1995. User's Guide: P2/FINANCE for Screen Printers (Version 1.0).
Boston, MA.
This User's Guide introduces P2/FINANCE for Screen Printers (Version 1.0) software
system, a tool designed to assist you in evaluating the profitability of pollution prevention
investments. This guide offers step-by-step instructions for installing and using the
P2/FINANCE-SP system. P2/FINANCE-SP was designed specifically for screen printers and
includes a Master List of costs and revenues specific to the basic screen printing processes.
This system also allows you to expand the list of costs and revenues so that the software can
be tailored to your business's operations. Developed by Tellus Institute with funding from
the U.S. EPA's Design for the Environment Program in cooperation with the Screenprinting
and Graphic Imaging Association International.
Available from: Tellus Institute
11 Arlington Street
Boston, MA 02116-3411
(617) 266-5400
U.S. Environmental Protection Agency. January 1976. Environmental Aspects of Chemical Use
In Printing Operations. Office of Toxic Substances. Washington, DC. EPA-560/1-75-005
[call #PB251406].
This document contains the proceedings for the conference on " Environmental Aspects of
Chemical Use in Printing Operations." Papers presented covered types of printing
processes, emissions regulations, and health hazards from printing effluents.
Available From: National Technical Information Service
5285 Port Royal Road
Springfield, VA
(703) 487-4650
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Annotated Bibliography of Selected References
U.S. Environmental Protection Agency. October 1983. Summary of Available Information on
the Levels and Control of Toxic Pollutants Discharges in the Publishing and Printing Point
Source Category. Effluent Guidelines Division. Washington, DC. EPA 44071-83-400 [call
#PB92231703].
Summary of information used to develop the effluent guidelines for printers. Includes
information on data gathering, water usage, toxic pollutant discharge data, and control and
treatment technologies employed in printing industry.
Available From: National Technical Information Service
5285 Port Royal Road
Springfield, VA
(703) 487-4650
U.S. Environmental Protection Agency. January 1988. Title III Section 313 Release Reporting
Guidance; Estimating Chemical Releases From Printing Operations. Office of Pesticides
and Toxic Substances. Washington, DC. EPA 560/4-88-004b [call # PB93205979].
This document was designed to assist printers in completion of Part III (Chemical Specific
Information) of the Toxic Chemical Release Inventory Reporting Form. General information
on toxic chemicals used, process wastes generated, and examples of data needs and
methodologies are included.
Available From: National Technical Information Service
5285 Port Royal Road
Springfield, VA
(703) 487-4650
U.S. Environmental Protection Agency. October 1989. Pollution Prevention in Printing and
Allied Industries: Saving Money Through Pollution Prevention (Draft). ORD Pollution
Prevention Office, Washington, DC.
Intended to provide a brief introduction to pollution prevention, including what it is, how
it can help save money, and where you can get additional assistance. Example technical
options available to printing and allied facilities are included.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. Office of Pollution Prevention. November 1989. Case
Studies from the Pollution Prevention Information Clearinghouse (PPIC): Printing.
Washington, DC.
Provides short (1-2 page) case studies of pollution prevention activities conducted at
printing establishments. Details regarding costs to implement practices and cost savings are
presented.
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Annotated Bibliography of Selected References
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. August 1990. Guides to Pollution Prevention: The
Commercial Printing Industry. Office of Research and Development. Washington DC
EPA/625/7-90/008.
This guide was designed to provide commercial printers with guidelines and options to
minimize both hazardous and non-hazardous wastes. Worksheets for use in developing waste
minimization options for a facility are included.
Available From: Center for Environmental Research Information
Document Distribution Center (G-72)
26 West Martin Luther King Drive
Cincinnati, OH 45268
(513) 569-7562
U.S. Environmental Protection Agency. September 1991. Achievements in Source Reduction
and Recycling for Ten Industries in the United States. Office of Research and Development,
Washington, DC. EPA/600/S-91/051 [call # PB92137470].
A collection of source reduction and recycling case studies presented to U.S. EPA as success
stories. The document includes two studies related to printing processes.
Available From: National Technical Information Service
5285 Port Royal Road
Springfield, VA
(703) 487-4650
U.S. Environmental Protection Agency. July 1993. Design for the Environment Printing
Project. Office of Pollution Prevention and Toxics. Washington, DC. EPA 744-F-93-003.
A fact sheet describing the Design for the Environment Printing Project.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. March 1994. Federal Environmental Regulations
Potentially Affecting the Commercial Printing Industry: Office of Pollution Prevention and
Toxics. EPA744-B-94-001.
This document presents a discussion of Federal environmental statutes potentially affecting
the commercial printing industry. It provides an overview of the regulations and the specific
chemicals used in the industry that may trigger particular regulatory requirements. This
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Annotated Bibliography of Selected References
document is intended for information purposes only and is not an official EPA guidance
document.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202)260-1023
U.S. Environmental Protection Agency. June 1994. Abstracts of Pollution Prevention Case
Study Sources. Office of Pollution Prevention and Toxics. Washington, DC.
EPA 742-R-94-001.
This document provides sources for pollution prevention case studies. It is intended to serve
as a reference guide for locating pollution prevention case studies with economic
information. Each source listing contains a short description of the contents, a contact
name and telephone number, and a price for the document.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. June 1994. Printing Industry and Use Cluster Profile.
U.S. Environmental Protection Agency. Office of Pollution Prevention and Toxics.
Washington, DC 20460. EPA 744-R-94-003.
This report presents a profile of the printing industry, defines a use cluster, and presents an
overview of the chemicals, technologies, and processes used in the printing industry.
Available from: Pollution Prevention Information Clearinghouse
Environmental Protection Agency
401 M Street, SW
Washington, DC 20460
(202)260-1023
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Annotated Bibliography of Selected References
U.S. Environmental Protection Agency. June 1994. Summary of Focus Group Discussion -with
Screen Printers and Lithographers for the Design for the Environment Printing Project.
Office of Pollution Prevention and Toxics. Washington, DC. EPA 742-R-94-004.
This report presents the methodology used to conduct the focus groups, provides an overview
of findings, and then summarizes the findings of screen printing focus groups and
lithography focus groups separately. Individual summaries of each focus group, the
facilitator's guides and the "mockups" presented at the focus groups are attached as
appendices.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. September 1994. Design for the Environment.
Cleaner Technologies Substitutes Assessment: Screen Printing Industry, Screen Reclamation
Use Cluster (Draft). Office of Pollution Prevention and Toxics. Washington, DC
EPA 744-R-94-005.
This document presents the Cleaner Technologies Substitutes Assessment (CTSA) for screen
printing screen reclamation. Developed by the Design for the Environment for use by
industry, this CTSA focuses on the use cluster of screen reclamation, -which is a process,
rather than a specific set of chemicals. The goal of the CTSA is to offer a complete picture
of environmental impacts, cost and performance issues associated with each option in order
to allow for an informed decision about which alternative is best for a particular situation.
Available from: Pollution Prevention Information Clearinghouse
Environmental Protection Agency
401 M Street, SW
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. October 1994. Design for the Environment Printing
Project. Screen Printing Case Study 2: Technology Alternatives for Screen Reclamation
(Draft). Office of Pollution Prevention and Toxics. Washington, DC.
A fact sheet describing the Design for the Environment Screen Printing Case Study 2 on
technology alternatives for screen reclamation. This case study presents descriptions of two
commercially available technologies, a description of a technology now under development,
and comparative cost, performance, and risk information for three reclamation technologies.
Available From: Pollution Prevention Information Clearinghouse
Environmental Protection Agency
401 M Street, SW
Washington, DC 20460
(202) 260-1023
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Annotated Bibliography of Selected References
U.S. Environmental Protection Agency. December 1994. Design for the Environment Printing
Project. Screen Printing Case Study 4: Work Practice Alternatives for Screen Reclamation
(Draft). Office of Pollution Prevention and Toxics. Washington, DC. EPA742-F-95-003.
A fact sheet describing the Design for the Environment Screen Printing Case Study 4 on
work practice alternatives for screen reclamation. This case study highlights simple changes
in work practices in the screen reclamation process that resulted in significant environmental
benefits in terms of costs, environmental impacts, and worker exposure.
Available From: Pollution Prevention Information Clearinghouse
Environmental Protection Agency
401 M Street, SW
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. December 1994. Design for the Environment Printing
Project. Screen Printing Case Study 5: Chemical Alternatives for Screen Reclamation
(Draft). Office of Pollution Prevention and Toxics. Washington, DC. EPA 742-F-95-004.
A fact sheet describing the Design for the Environment Screen Printing Case Study 5 on
chemical alternatives for screen reclamation. This case study highlights one of eleven
alternative systems demonstrated in the DfE project, describing performance evaluations,
health and environmental risks, and costs of the alternative system.
Available From: Pollution Prevention Information Clearinghouse
Environmental Protection Agency
401 M Street, SW
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. August 1995. Multimedia Compliance/Pollution
Prevention Assessment Guidance for Lithographic Printing Facilities. U.S. Environmental
Protection Agency, Office of Enforcement and Compliance Assistance.
U.S. Environmental Protection Agency. August 1995. EPA Office of Compliance Sector
Notebook Project - Profile of the Printing and Publishing Industry. Office of Compliance.
Washington, DC. EPA/310-R-95-014.
This document is pan of the EPA Office of Compliance's Sector Notebook Project. It
provides a variety of summary information for the printing and publishing industry,
including general industry information, a description of industrial processes, pollution
issues, and the Federal statutory and regulatory framework.
Available From: Superintendent of Documents
U.S. Government Printing Office
Washington, DC 20402
(202) 512-1800
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Annotated Bibliography of Selected References
U.S. Environmental Protection Agency. Undated. Design for the Environment Printing Project:
Case Study. Design for the Environment Program; Office of Pollution Prevention and
Toxics. EPA 744-K-93-001.
First in the series of case studies that illustrates the Design for the Environment theme. The
study describes the successful pollution reduction program of a printing company in
Minnesota. The company searched for safer alternatives to managing solvents and wipes.
The case study explains the methodical evaluation of the problem leading to solutions aimed
at reducing the creation of pollutants at their source.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. Undated. Design for the Environment Printing Project.
Screen Printing Case Study 2: Reducing the Use of Reclamation Chemicals in Screen
Printing (Draft). Office of Pollution Prevention and Toxics. Washington, DC. EPA 744-
F-93-015.
A fact sheet describing the Design for the Environment Screen Printing Case Study 2 on
reducing the use of reclamation chemicals in screen reclamation. This case study shows (1)
how a self-audit of ink remover products used in screen cleaning led to the substitution of
more environmentally appropriate solvents, (2) how using a still to recover and reuse ink
cleaning solvent saved the money, and (3) how using a high-pressure water blaster and
changing product application techniques allowed the company to decrease its use of
reclamation chemicals.
Available From: Pollution Prevention Information Clearinghouse
Environmental Protection Agency
401 M Street, SW
Washington, DC 20460
(202) 260-1023
U.S. Environmental Protection Agency. Undated. Printing and Publishing Information Packet.
Compilation of information on printing and publishing.
Available From: Pollution Prevention Clearinghouse
Environmental Protection Agency
401 M Street, SW (3401)
Washington, DC 20460
Venell, Susan. August 1985. Water-Based Inks: Why The Diluted Response? Screen Printing,
Vol. 75, No. 8.
This article discusses why water-based inks, although readily available to the screen printing
industry, have not been widely accepted. Problems associated with water-based screen
printing and possible activities hindering acceptance of water-based inks are discussed.
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Annotated Bibliography of Selected References
Virginia Department of Environmental Quality. September 1993. Printers Win Through
Pollution Prevention (Video). Waste Reduction Assistance Program.
"Real Life" pollution prevention options for printers are highlighted in this video. A list of
vendors and associations that may provide information beneficial to printers accompanies
the video.
Available From: Waste Reduction Assistance Program
Virginia Department of Environmental Quality
Office of Pollution Prevention
P.O. Box 10009
Richmond, VA 23240-0009
(804) 762-4344
Virginia Waste Reduction Assistance Program. 1991. Waste Reduction Fact Sheet: Waste
Reduction for the Commercial Printing Industry. Vol. 1, Issue 2.
Short fact sheet on steps to reduce waste, and the toxicity of waste streams from printers.
Available From: Virginia Department of Environmental Quality
Office of Pollution Prevention
P.O. Box 10009
Richmond, VA 23240-0009
(804) 762-4344
Washington State Department of Ecology. September 1994. Environmental Management and
Pollution Prevention: A Guide for Screen Printers. Washington State Department of
Ecology Environmental Management and Pollution Prevention.
A guide focusing on (1) encouraging pollution prevention as a first step toward better
environmental management on the print shop level and (2) educating the printing industry
on applicable Federal, State, and local environmental requirements and options available
to meet those requirements.
Available from: Department of Ecology
Eastern Regional Office
North 4601 Monroe, Suite 202
Spokane, WA 99205-1295
(509) 456-2926
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