v-xEPA
                United States Environmental
                Protection Agency
Region 9
(WST-i-i)
EPA 909-E-99-001
November appp
                Best Environmental Practices
                for Auto Repair



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                                                                                           November 1993
          PROFIT   THROUGH   PREVENTION
         Best Environmental Practices for Auto  Repair and  Fleet Maintenance
Getting Started
The step-by-step instructions in this fact sheet can help you reduce
waste, avoid regulatory problems, and save money! This fact sheet is
the first in the "Pollution Prevention Tool Kit," a series of fact sheets
highlighting the Best Environmental Practices for auto repair shops
and fleet maintenance facilities. This fact sheet contains the following
information:
• Step-by-step instructions for reducing your waste generation
• Tables to help you assess your waste stream volumes and costs
  before and after implementing the recommended practices
• References to other fact sheets in the series that contain detailed
  information on recommended practices
• Specific guidance on how common auto repair and fleet maintenance
  shop wastes are regulated.


How to Minimize Your Waste Generation Now
Use the table on page 2 to inventory your current practices and waste
streams. Then refer to the recommended Best Environmental Practices
described in the fact sheets cited on page 3. Test and implement as
many recommended practices as possible, and then re-inventory your
waste streams on page 3.
If you reduce your total monthly volume of
hazardous waste to less than 220 pounds or
27 gallons, you will have significantly fewer haz-
ardous waste regulations to comply with.
Remember that a hazardous waste may never be
discharged into a sanitary sewer, storm drain,
ditch, dry well, or septic system!
is your waste hazardous?
You are ultimately responsible for determining whether the wastes
generated in your shop are regulated as hazardous wastes. You can
apply your knowledge of shop operations and of the materials you
use to determine whether a waste is regulated as a hazardous waste.
If you suspect that a waste may be hazardous but are not sure, either
assume that it is hazardous and pay for proper waste disposal or
recycling, or have the waste tested to get a definitive determination.
Local laboratories and hazardous waste disposal companies can
sample and test a waste for you using approved methods. The test
results will tell you whether the waste is hazardous or not. If it is not
hazardous, and if both the chemicals and process you use to generate
that waste do not change, you can rely on the test results for that
one sample as proof that the waste is not hazardous in the future.
That is, the waste generated by the process in the future will be
assumed to have characteristics similar to the current waste. Make
sure to keep a copy of each test result in your files in case a haz-
ardous waste inspector ever questions your waste determination.
Your air emissions and sanitary sewer discharges are regulated by
your local air district and sewer agency, respectively. You should con-
sult them about air and sewer discharge requirements.
REDUCING YOUR WASTJE = FEWER HAZARDOUS WASTE REGULATIONS
Large Quantity
Generator (LQG)
2,200 Ibs or 275 gallons
or more per month
5 drums or more per mo.
At least 78 regulations
V
• Small Quantity __
Generator (SQG)
220 to 2,200 Ibs or
27 to 275 gallons per month
1/2 drum to 5 drums
At least 67 regulations
Conditionally Exempt Small
Quantity Generator (CESQG)
220 Ibs or 27 gallons
or less per month
Less than 1/2 drum
Just 3 regulations!
(see back page for details)

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                     BEST ENVIRONMENTAL PRACTICES FOR AUTO REPAIR AND  FLEET MAINTENANCE
Process
Parts Washing
Coolant Changing
Brake Washing
Lubricating and
Spot Cleaning
Floor Cleaning
Other Processes
Traditional Practice
Solvent Service
Off-site Recycling or Disposal
Aerosol Spray Cans
Solvent Service
Aerosol Spray Cans
Disposable Rags or
Paper Towels
Dry Absorbents
Hosing With Water"
Cleaning Service

Waste Stream
Waste Solvent A
Waste Antifreeze5
Waste Cansc
Waste Solvent"
Waste Cansc
Used Rags or Paper Towels6
Used Rags or Paper Towels6
Used Absorbent'
Trap or Separator Sludges °
Wash or Mop Water"
Waste Gasoline, etc.
Is Waste
Hazardous?
(use notes below)











Determine your generator status by adding up the quantity of all hazardous wastes
(Multiply gallons by 8 to convert to pounds)
Determine your monthly waste management costs for all waste streams
Amount per Month
Quantity of
Hazardous Waste












Disposal
Cost












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        sStream	
lBiiM
 IIIDDDIH
                       itory Guidance for "Traditional" Practices
                            dges are generally hazardous unless testing demonstrates otherwise.

                            1     I  11  II  I
       _!___	jji^r^jj-j^jj^^ug Jgig^fog 0n jts metal concentration. In a 1999 federal survey of


           samples proved to be Hazardous wastes. If waste antifreeze is hazardous, you may not discharge it into a sanitary sewer, storm
 IE
                    6F septic system. Some states exempt recycled waste antifreeze from hazardous waste regulations. If you recycle waste
                    Illllllllllllllillllllillllllllllllllll
        •II in such a state, do not count it as a hazardous waste. Otherwise, test your waste antifreeze or count it as a hazardous waste.

        aerosol cans should be disposed of in trash or recycled as scrap metal if they are completely empty. Dispose of used aerosol cans as

            [waste	JLtbey are 05*.?E!Rty anc' t^eir contents arehazardous.' Dp not count empties as hazardous waste.
                                     IilllllllllllIIHlll
                                     keiy to be a hazardous waste.
            and paper towels are very likely to be a hazardous waste if they are contaminated with gasoline or solvent. If trie solvent product

      cdcontained an F-tisted chemical at a 10% or greater concentration, the contaminated rags or towels will be a hazardous waste
      	..,...,,,	•	'•(•	in	,	i	««««	<	
                   Histed Chemical" on page 4). If solvent on rags or towels is not an F-listed chemical, use your knowledge or test the rags
                   	lllgiiiillK^                                                                                    	!	BlnWIIIIIILllllW   	«	i!
                      ie whether they are hazardous. If they are hazardous, it is illegal to dispose of them in trash. Have used rags laundered

               anIndustnal laundry, or dispose of them as a hazardous waste!
B^^^^^QI
                                                                                        IViiHMlin
        absorbents soaked with waste oil are not federally regulated, unless they are also contaminated with hazardous wastes. Some states
        IIIH                                                                                                        	
       (late oily wastes and may count oil-soaked absorbents as hazardous waste, unless recycled in accordance with state law.
    •Judges from traps and oil/water separators may contairi'n'eavy metals or solvents. Test sludges at least once to determine whether they

           icavy metals or solvents.
IE
            er or mop water is generally not counted as a hazardous waste! However, if wash or mop water meets the criteria for a hazardous


                riot be placed in a sanitary sewer!yprlelxample,lllwalshlinglllgasoline into "the dram would be' illegal disposal of a hazardous waste      I

                                     pf	||!l,JUIjB»
                 chgrge reguirernents limiting its oil and grease content, etc. Check with your sewering agency for requirements

                                                                                                       HKHIflSiSIKM
                                                                                                       latteries are not addressed      \
UIBIMSS3S3
              they are recycled In accordance with state and federal laws,_they_are npt_countea_ as hazardous wastes when determining gen-

             7fwu£shpD does not recycle these materials, follow state taws"
                                                                                                                        IlillLLIIllliiiiillliilPi 'liilllllllllllllllPiilitliiJ'JI11,!1!!!!!!!!! I

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                   BEST ENVIRONMENTAL PRACTICES FOR AUTO REPAIR AND  FLEET MAINTENANCE
STEP 2:  Implement as many best practices as you can
Refer to the enclosed fact sheets.
STEP 3: Calculate your new generator status
After implementing as many Best Practices as possible, recalculate your waste volumes and costs.
Process
Parts Washing
Coolant Changing
Brake Washing
Lubricating and
Spot Cleaning
Floor Cleaning
Other Processes
Best Practice
Aqueous Spray Cabinet,
Ultrasonic unit,
Microbial Sink-top,
or Immersion unit
On-site or Off-site Recycling
Aqueous Brake Washing
Refutable Spray Bottles
Spill Prevention and
Dry Cleanup Methods

Waste Stream
Waste Filters'
Waste Aqueous Solution1
Sludges or Resins"
Waste Filters'
Waste Solution1
Used Rags or
Paper TowelsE
Used Rags or
Paper TowelsE
Mop Water"
Used Absorbent"
Waste Gasoline, etc.
Is Waste
Hazardous?
(use notes below)









Determine your new generator status by adding the monthly quantities of all hazardous wastes.
(Multiply gallons by 8 to convert to pounds) Compare the total quantity to the Step i total.
Estimate your new monthly waste disposal costs for all waste streams. Compare the total cost to Step i total.
Amount per Month
Quantity of
Hazardous Waste




-






Disposal
Cost









jr;
£
j


.... 	


	


Waste Stream Regulatory Guidance for Best Practices
' Waste metal filters should be recycled with oil filters as a "hazardous waste-exempt scrap metal waste"; other waste filters should be disposed
 of as a hazardous waste or tested. In one study, one out of two filters tested positive as a hazardous waste because of the presence of lead.
1 Waste aqueous solution should be shipped off site as a hazardous waste or tested. In two studies, 75 percent of waste aqueous solutions
 tested positive as hazardous wastes because of their lead and cadmium concentrations. Microbial solutions may last for years. Extend
 solution life by pre-cleaning parts with a(rag, filtering, and removing oil.
K Antifreeze-recycling sludges or resins should be shipped off site as a hazardous waste or tested. In a 1999 federal survey of sampling studies,
 about half the waste antifreeze samples proved to be hazardous wastes due to metals content. Antifreeze recycling sludges and resins are
 likely to contain even higher concentrations of metals than waste antifreeze.
1 Antifreeze recycling filters made of metal should be recycled with oil filters as a "hazardous waste-exempt scrap metal waste"; for nonmetal
 filters, make your own determination based on your process knowledge or testing.
M Mop water should  be nonhazardous and can be disposed of in a sanitary sewer, provided that all floor spills are first cleaned up using dry
 cleanup methods. If the floor drain is capped, pour the mop water into a sink or flush it down a toilet (local sewer agency approval is required).
 Mop water and other waste material should never be discharged to a storm drain, ditch, dry well, or septic system.
" Used absorbent should be used only to clean up gasoline or solvent spills; in emergency situations; or for cleanup of old, pitted shop floors.
 Test the used absorbent or use your knowledge of what was spilled to determine whether the used absorbent is hazardous. Absorbent satu-
 rated with gasoline or solvents will very likely be a hazardous waste.
Note: Used oil; brake, transmission, and hydraulic fluids; oil filters; refrigerants from air conditioning systems; and batteries are not addressed
here  because if they are recycled in accordance with state and federal laws, they are not counted as hazardous wastes when determining gen-
erator status. If your shop does not recycle these materials, follow state laws.

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                          BEST ENVIRONMENTAL PRACTICES  FOR AUTO REPAIR AND FLEET MAINTENANCE
                               Means to Your Shot
             enf ratg legs than 220 pounds per month o
             •"a
                                              azardous wastes (about 27 gallons of a liquid with tr
    B
HB3BS1
                      siaye sgnificantly fewer hazardous waste requirements to comply with and many more waste management options.
        n to local air pollution regulations and wastewater discharge rules, a CESQG need comply with only'th'ree basic hazardous waste
ggnagemeni requirements:
  dentify all hazardous waste you generate;
    iiliiiiiiiiiiiiilliiB
    liBsistiamgiiJlan	2,200 pounds
                     ite at any one time;

  |eg!uma|§iy use, reuse, or recycle your waste on site, or ensure
             lyr hazardous waste to	one	of the	following:
              lerally regulated hazardous waste treatment,
    a^^^r^EOSaiT^iM	CTSDQ	'   '	"'	'"
                                  iillliiiliillilllililiiiliiliVSiSiiMlill
                                          / the state to
                Mm^^^^i^p^^ii^'-^i^	

                             s, reuses, or recycles'tKe'wasfe
                    prior to its use, reuse, or recycling
              ,	,            „
              hazardous waste collection center run by your
   il^^no«TgovernmenVlfa_yailableV
       Sfsme states "required

                        ariJifSUaentiflcatiori number or further restrict-
          i IlSJJolaf opf/ons. Call your state hazardous waste agency for
          	ii!	iiiiiniiiiiH  	
                  inflation.
                                                                       What is an F-Listed Chemical?
                                                                       An F-Listed chemical is a chemical that makes each waste it contaminates
                                                                       a hazardous waste no matter what its concentration in the waste is.
                                                                       Even one drop of an F-listed chemical on a shop rag, in absorbent, or in
                                                                       used oil or antifreeze is enough to make a regulated hazardous waste.
                                                                       Find out which products in your shop contain F-listed chemicals, and be
                                                                       very careful not to contaminate your wastes with them. Check the
                                                                       Material Safety Data Sheet (MSDS) for each product you use. If the
                                                                       product is an aerosol or liquid solvent (parts cleaner, brake cleaner, etc.)
                                                                       and has any of the following chemicals in it at a concentration of 10 per-
                                                                       cent or more, all waste streams contaminated by the product must be
                                                                       properly managed as hazardous wastes: acetone; methanol; 1,1,1-
                                                                       trichloroethane; methyl ethyl ketone; methyl isobutyl ketone; xylenes;
                                                                       benzene; ethyl benzene; toluene; perchloroethylene; trichloroethylene;
                                                                       and dichloromethane (methylene chloride).


••Ill
                   pollution Prevent/on 'Tom Kit is a "great resource for our industry. Repair shops can realize "significant 'compliance
                      ana cost savings by following the soun^^
                                        	'	  	  "	"'"	"ifbrnia
                                                                            Past President; Automotive	Service	Coilncils'oT
                                   	,  ,

                       locaj governrnent envjronmental agency has more information about compliance and pollution prevention for auto repair shops an
            fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/p2/autofleet.
                       t is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
                             llllllH^                                                                                             	"lllm	
                     llcatlon number EPA-gog-E-gg-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
                   i number EPA-909-E-99-002). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention"
                      ile atthe sajJig^lioi^'nun^b^fw either auto repair (numberEM-gog-y-gg-ooy or fleet maintenanoe uiuni^er ERA-goj-V-gg-oozj.
            / tfe€»e f»c* sh««U w«e produced by '!>?, E"*0",!"6"^! 1ftPt6E?ton, Asen^y (EPA) Region 9 pollution prevention program.

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                       AQUEOUS   PARTS  CLEANING
                                                    Best Environmental Practices for Auto Repair • November 1999
Myth
0 Aqueous cleaning units
  do not clean parts as well
  as solvent units.
Fact
Aqueous spray cabinets can clean
even difficult-to-clean parts such
as wheel bearings.
© Part rusting is a problem.
Rust inhibitors in aqueous
cleaners decrease the chances
of rusting. Rusting can be
further minimized by drying
parts immediately after cleaning.
© Aqueous cleaning
  is expensive.
Most shops can save money by
i) implementing aqueous spray
cabinets to reduce cleaning labor
and 2) maximizing aqueous
solution life.
O Aqueous cleaning wastes
  are a hassle to manage.
Waste aqueous solution with
sludge typically requires disposal
less than three times per year.
Skimmed oil can be recycled
along with used oil. Spent filters
can be disposed of off site or
sometimes recycled along with
used oil filters.
What's wrong with solvents?
Mineral spirits is a solvent commonly used for part cleaning
because of its ability to quickly dissolve oil, grease, dirt,
grime, burnt-on carbon, and heavy lubricants. Although it is
effective for cleaning, mineral spirits raises significant environ-
mental and human health concerns:
• Mineral spirits contains volatile organic compounds (VOC) that
 contribute to smog formation and may be toxic when inhaled.
• Mineral spirits evaporates quickly, making worker exposure
 difficult to control.
• Spent mineral spirits is a hazardous-waste and the shop owner
 is responsible for proper disposal of all hazardous wastes.
• Some areas of the country have already restricted use of
 solvents in parts cleaning operations.
Using solvents creates unnecessary environmental, worker
health, and fire liabilities for your shop. Minimize your costs
and liabilities by switching to aqueous solutions.


What is an aqueous  cleaner
and how does it work?
Aqueous cleaners are water-based solutions that, unlike petrole-
um- based solvents, are typically nonflammable and contain
little or no VOCs. Instead of dissolving grease and solids, aque-
ous cleaners rely on heat, agitation, and soap action to break
dirt into smaller particles. Although they clean differently,
aqueous cleaners perform as well as solvents.
For this fact sheet, aqueous cleaners are defined as water-
based cleaners that contain less than 5% (50 grams per liter)
of VOCs. Hundreds of aqueous cleaner formulations are com-
mercially available. The California South Coast Air Quality
Management District maintains a list of aqueous solutions that
are certified to contain less than 5% of VOCs; this list is avail-
able on the Internet at www.aqmd.gov/tao/cas/prolist.html.
Information presented in this fact sheet is derived from  studies
of more than 20 aqueous cleaning units in use at over 30
shops in California.
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           Aqueous Parts Cleaning
           Types of aqueous cleaning units
           The cleaning equipment used is critical to successful aqueous cleaning because it applies two important mechanisms to the cleaning process:
           mechanical force and heat. Two types of aqueous cleaning units that are applicable to most auto repair shops—microbial sink-top and spray
           cabinets—are described below. Most shops will likely meet all their cleaning needs by implementing both types of units. Specialty shops that
           clean many transmissions and carburetors may also want to investigate using ultrasonic and immersion type units (not covered here). For
           information on all types of aqueous cleaning units, see the fact sheet "Case Studies in Aqueous Parts Cleaning".
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Spray cabinets:
For heavily soiled or large
volumes of parts
Aqueous spray cabinets clean parts by
spraying high-temperature solution
at high pressures within an enclosed
cabinet. Spray cabinets are available in
a full range of capacities from small to
extremely large.
Applications
• Parts with heavy or difficult-to-remove soils
• Moderate to very large quantities of parts
• Medium to large sized parts
• Heavy-duty repairs and rebuilding
Key Features
• Solution heated to 130 to i9o°F
• Oil skimming options
• Solution concentration typically maintained between 10 and 15%
Microbial sink-top units:
Best for quick, light-duty cleaning
Aqueous sink-top units are used for manual cleaning of parts in the
same way as conventional solvent sink-top units. Microbes present
in the aqueous solution degrade oils and organic contaminants, sig-
nificantly extending solution life. In addition, microbes are safe and
pose no risk to technicians. Non-microbial aqueous sink-top units
are also available; these units generally require more frequent solution
changes, which may increase operating costs relative to microbial units.
•••••••••MaH^M^^^^^^^^^^^^MMHMMMBHHMBHBHMMMMlHHMl^^^^^^^^^^M^HHMMMMHMBHaMMII
Applications
• Preventive maintenance and light-duty cleaning
• Parts with light to moderate soil buildup
• Small quantities of parts
• Parts for immediate replacement on a vehicle
           Advantages
           • Significant reduction in cleaning labor
           • High level of cleaning performance
           > Large cleaning capacities available
           • Lower waste management costs compared to solvent units
                                                                           Key Features
                                                                           • Solution heated to 110 to i2o°F
                                                                           • Filtering available to remove
                                                                            solids
                                                                           • Microbes degrade oily contaminants
                                                                            significantly extending solution life
                                                                Advantages
                                                                • Low capital cost relative to
                                                                  other aqueous cleaning units
                                                                • Little or no waste solution
                                                                • Does not dry or chap technician's hands
           Disadvantages
           • Moderate to high cost
                                                                Disadvantages
                                                                • May require more scrubbing effort than solvent
                                                                • Difficult to clean heavy or stubborn soils
                                                                • Keeping microbes alive requires proper worker training
           Unit Selection Considerations
           • Pump power, spray pressure, flow rate, and number of nozzles
            (higher spray pressures and greater coverage result in better
            cleaning performance)
           • A 220-voIt outlet is often required
           • Temperature adjuster helps to optimize cleaning performance
           • Insulated units are more energy efficient
                                                                Unit Selection Considerations
                                                                • Make sure the unit is at a comfortable height for your workers
                                                                « Greater sink-top size allows larger parts to be cleaned
                                                                • Higher pump pressure improves cleaning action
                                                                • Workers may react negatively to certain odors
           Cost! $1,700 to $5,500
                                                                Cost: $1,000 to $1,500

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                                                                                    Best Environmental Practices for Auto Repair
Maximizing aqueous solution life
Aqueous cleaning solutions can last longer than solvents. Further
extending the life of an aqueous solution will save you money
by reducing your chemical purchase and waste disposal costs.
To maximize aqueous solution life, you should:
Use microbe technology for sink-top units. Solutions for these units
have very long lives and with proper use rarely require disposal.
Filter the solution. Filters, typically cartridge filters, are used to
remove solids as small as 50 microns in size.
Perform oil skimming. Oil skimmers remove free-floating oil from
the solution, reducing the amount of oil residuals left on parts and
significantly extending solution life. Microbial units do not need oil
skimming because microbes degrade the oil.
Accept solution discoloration. Many aqueous solutions turn gray
or brown during use, but this discoloration does not affect cleaning
ability. Do not change your cleaning solution just because it looks dirty.
Change the solution only when necessary. Change the solution
only when its cleaning performance declines. Do not change the
solution on a scheduled basis. Always dispose of cleaning solution
appropriately.
Maintain solution concentration. Perform chemical additions as
needed to maintain the cleaning strength of your solution. Some
vendors offer easy-to-use test kits to measure the  concentration of
your solution and determine when chemical additions are necessary.
Recycle your solution using microfiltration. Some  vendors offer
an on-site microfiltration recycling service that removes contami-
nants from the solution, eliminating waste solution generation
and disposal.
  Unit Selection Tips
  Check References: Obtain and check vendor references to
  determine the unit cleaning performance and maintenance
  requirements at other shops.
  Demonstrate the Unit: Demonstrate a unit and aqueous solu-
  tion before making a purchase. Most vendors allow shops to
  demonstrate units for 2 to 4 weeks at no cost.
   solution life
    "I've used the same solution in my microbial sink-top unit
   for 2 1/2 years, and it's still going strong."
                                          —Ted Patterson
                         Ed's Auto Clinic, Fremont, California
Killing your microbes will result in an upleasant odor, oil
accumulation in your solution, or loss of cleaning performance.
Be sure to keep your microbes alive and happy!
Keeping your microbes happy
Maintain solution temperature: Don't unplug your microbial sink-
top unit, even overnight. Most microbes require a heated environ-
ment to survive.
Don't use aerosols above unit: Solvents from aerosols and other
sources may harm microbe populations and contaminate the solution.
Allow time for microbes to adjust to new soils: Microbes will adapt
to the type of soils you are cleaning. If the microbe solution does
not clean effectively at first, cleaning performance will improve
after the microbes adapt and digest the new soils.
Don't overload the unit: Do not pour oils or dump soils into the unit.
Sudden loading of concentrated oils and grease may harm the
microbes. Very heavily soiled parts should be precleaned by wiping
with a rag.
Monitor sludge and oil accumulation: Solids will gradually accumu-
late at the bottom of the solution, decreasing cleaning performance,
and therefore may require removal every several years. Also, an oil
layer may accumulate on top of some solutions. If the unit does not
have aeration, significant oil accumulation may suffocate the microbes
and should be skimmed off.
O
70

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          Aqueous Parts Cleaning
LU

1
19
5
3
Managing aqueous cleaning wastes
The wastes generated from aqueous cleaning should be managed
as described below.
Waste Solution. Aqueous cleaning solutions may qualify as
hazardous waste after extended use because concentrations of
metals such as cadmium, copper,  lead, and zinc may exceed state
or federal limits. Therefore, auto repair shops should always use
a licensed waste disposal company to manage waste solution.
Many waste disposal companies will analyze the waste solution
for you to determine whether it is hazardous. The cost of disposal
will vary according to the characteristics of the waste and the vol-
ume generated, but will generally be $2 to $4 for a gallon if it is a
hazardous waste and $1 to $2 for nonhazardous waste. Unless you
obtain permission from your local sewage treatment agency, do
not dump waste solution in the sewer or septic system.
Used Filters. Used filters may be recycled along with spent engine
oil filters with the permission of the recycler. Contact your oil recy-
cler to determine if they will take your filters. Some recyclers will
only accept used filters if they are encased in metal shells like
engine oil filters, and some states prohibit recycling aqueous filters
with engine oil filters. If they are not recycled with engine oil filters,
used filters should be managed as hazardous waste and disposed
of by a licensed waste disposal company. Contact your state envi-
ronmental agency to learn if any special rules apply to used filters.
Skimmed Oil. Oil skimmed from an aqueous cleaning solution can
be managed as used oil and recycled. Most recyclers will accept
skimmed oil with used motor oil as long as it is not contaminated
with solvent
Simple sludge management
Little or no sludge will accumulate in aqueous cleaning units with
filtration, but units without filtration may accumulate sludge at the
bottom. This sludge may be disposed of along with waste solution.
Most waste disposal companies will accept a certain percentage of
solids in the waste solution. If the sludge is separated from the
solution, the sludge may not be disposed of as solid waste unless
tested to determine if it is nonhazardous.


Full service lease agreements
Convenience at a cost. Most auto repair shops enjoy the hassle-
free arrangement of full servicing and waste management provided
by a solvent management company. Although some aqueous clean-
ing vendors offer similar servicing and waste management arrange-
ments, most do not, usually because it's not necessary. Here's why:
. Aqueous solutions can
 last significantly
 longer than solvents
 and therefore do not
 need to be changed
 as frequently. Even
 with heavy use, a
 spray cabinet can clean effectively for as long as 3
 months between solution changes. With proper use, microbial
 sink-top units may clean effectively for several years before
 requiring solution change.
• Servicing aqueous units requires minimal time and effort.
Self servicing aqueous cleaning units may be easier than you think!
             Microbial Sink-Top Units Generate
             Waste Solution
             (every several years)
             • Send off-site as hazardous
              waste or sample to demonstrate
              solution is nonhazardous
             Used Filters
             (every 3 weeks to every 6 months)
             • Dispose as hazardous waste or
              with engine oil filters if permitted
                                                                Spray Cabinets Generate:

                                                                Waste Solution
                                                                (every month to every 6 months)
                                                                • Send off site as hazardous waste
                                                                  or sample to demonstrate
                                                                  solution is nonhazardous
                                                                • Include sludge


                                                                Skimmed Oil
                                                                (every 2 weeks to every 2 months)
                                                                • Recycle with used motor oil
              waste management
              "The only wastes our microbial sink-top generates are filters, which are replaced 3 times per year."              — Bruce Ackerman
                                                                                        Ackerman's Volvo Service, Berkeley, California

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                                                                                 Best Environmental Practices for Auto Repair
Aqueous cleaning cost worksheet
Use this worksheet to estimate costs and savings associated with switching from solvent to aqueous cleaning. This worksheet can be used to esti-
mate costs to convert from one or more solvent units to a microbial sink-top unit, a spray cabinet, or both a microbial sink-top and spray cabinet.
The sample calculations provided are for a shop with two solvent units that converts to one microbial sink-top unit, which handles 40%
of the original cleaning workload, and one spray cabinet, which handles 60% of the original workload. The values provided in the sample
column serve only as an example, as actual costs and savings will vary according to shop-specific conditions.
CURRENT SOLVENT CLEANING COSTS (leased units with servicing)
A Number of solvent units leased
B Current cost per service visit per unit
C Number of times unit serviced per year
D Total annual solvent service cost (A x B x C)
E '. Cost of electricity used per year per unit
F ; Total cost of electricity used (A x E)
G Loaded hourly labor rate of shop worker
H Total number of cleaning labor hours per week
1 Total yearly labor cost (GxHxs2)
j Total annual cost for solvent cleaning (D + F + 1)
CONVERSION TO MICROBIAL SINK-TOP CLEANING UNITS
K Number of microbial sink-top units to be purchased
L : Unit purchase price
A/I Total capital cost of sink-top units (Kx L)
N Cost per gallon of aqueous cleaner
0 Estimated aqueous cleaner use per year in gallons
P Aqueous cleaner purchase cost per year (N x 0)
Q Cost per replacement filter
R Number of replacement filters per year
S Total cost for replacement filters (QxR)
T Cost of electricity use per year per unit
U : Total number of cleaning labor hours per week
V ; Total yearly labor cost (G x U x 52)
W Total sink-top unit operation and maintenance (O&M) cost ( [P + S + T] x K +V)
CONVERSION TO AQUEOUS SPRAY CABINET CLEANING UNITS
X Number of spray cabinets to be purchased
Y ; Spray cabinet purchase price
Z Total capital cost of spray cabinets (XxY)
AA Cost per gallon of aqueous cleaner
BB Estimated aqueous cleaner use per year in gallons
CC Aqueous cleaner purchase cost per year (AA x BB)
DD Cost per gallon of spent solution (including sludge) disposal
EE Gallons of solution in spray cabinet
FF Number of solution changes per year
GG Total cost for spent solution disposal (DD x EE x FF)
HH Cost of electricity use per year per unit
II Number of cleaning hours per week (typically reduced by 80%)
JJ Total yearly labor cost (6x11x52)
KK Total yearly spray cabinet O&M cost ( [CC + GG + HH) x X + JJ)
RESULTS
LL Total capital cost (sink-top and spray units) (M + Z )
MM Total cost savings (including labor) 0 - W - KK)
NN Payback period in years (LL-^MM)
V
your facility










your facility













your facility
-















-

sample
- 2
".- $159
— 6
$1,908
- y $280
$560
$50
5
" $13,000
$15,468
sample
i
^ $1,295
$1,295
$6
48
~ $288
$10
4
$40
$300
2
$5,200
$5,828
sample
i
$3,000
$3,000
$6
48
$288
$3
35
2
$210
$500
0.6
$1,560
$2,558

$4,295
$7,082
0.6
                                                                                                                               8
                                                                                                                               o
                                                                                                                               73

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          Aqueous Parts Cleaning
in
HI
Case study:
Larry's Autoworks
Larry's Autoworks is a full-service auto repair shop with six techni-
cians and 14 bays. Previously, Larry's used 12 labor hours per week
to clean parts using two mineral spirits units that were serviced
every 6 weeks. In January 1998, Larry's replaced these units with a
large EMC Model 100 aqueous spray cabinet purchased used from
a vendor and an EcoClean Bioflowao aqueous microbial sink-top
unit Larry's performs 90 percent of its part cleaning in the spray
cabinet, which has reduced cleaning labor by 60%. Larry's uses the
microbial sink-top unit to clean only small parts and parts with
painted surfaces that might be damaged in the spray cabinet. The
spray cabinet solution and sludge are disposed of as separate
waste streams every 6 months by a waste disposal company. The
microbial unit has not required solution disposal in over 16 months
of continuous use. Owner Larry Moore says: "The spray cabinet has
Improved our produc-
tivity as well as the
cleanliness of our
parts. We even use it
to keep our equipment
clean, resulting in an
overall cleaner shop."
          The aqueous spray
          cabinet that Larry's
          Autoworks purchased
          used for$1,600 performs
          po% of Its part cleaning.
                                                                         Case study:
                                                                         Auto Electric and Fuel
                                                                         Auto Electric and Fuel has three technicians, performs light-duty
                                                                         cleaning of small parts, and previously used a mineral spirits unit
                                                                         that was serviced every 8 weeks. The shop contracts large cleaning
                                                                         jobs out to a local steam cleaning business. The shop switched to
                                                                         an EcoClean  Bioflow2o aqueous microbial sink-top unit in spring
                                                                         1997 and has not disposed of any solution since that time. The
                                                                         shop cleans more difflcult-to-remove soil by first soaking the parts
                                                                         in a small container placed in the sink-top unit. The shop is now
                                                                         saving $940  per year using aqueous cleaning, and the payback
                                                                         period for the sink-top unit was 1.5 years. The shop owner says:
                                                                         "The solution is nice and warm, much easier on technicians' hands
                                                                         than solvent. The unit meets our cleaning needs very well."
    total cost
    "Eliminating scheduled servicing by the solvent manage-
    ment company saved us significant money. We estimate
    $940 per year savings using aqueous cleaning."
                                           — Doug Mueller
                    Auto Electric and Fuel, Concord, California
                                                                    PARTS CLEANING COSTS COMPARISON
           "Our spray cabinet
           reduced our cleaning
           labor 60%, increasing
           our overall productivity."
                       —Larry Moore
                   Larry's Autoworks
             Mountain View, California
                                     Two Solvent Units
                                               Annual costs
                               Leasing, waste
                               management	$1,260
                               Electricity (est.)	$1,400
                               Cleaning labor	$31,200

                               Total costs	$33,860
     Larry's cost summary
                         I
   Aqueous spray cabinet
                         i
               Annual costs
Purchase price
(one-time)	$1,600
                         ir
Chemical use	$75
Solution and sludge
disposal	$425
Electricity (est.)	$3,100
Cleaning labor	$11,232
 Aqueous Microbial Sink-top
                Annual costs
Purchase price
(one-time)	$1,300
Chemicals	$325 .
Filters	$60
Servicing 	$289
Electricity (est.)	$360
Cleaning labor	$3,120
                                                                        Total costs	$16,432      Total costs  	$5,454
                                                Total Capital Cost: $2,900 •  Annual Savings: $14,874 •  Payback Period = 0.2 Year

-------
                                                                                    Best Environmental Practices for Auto Repair
Case study:
Glenmoor Auto Repair
Glenmoor Auto Repair is a full-service auto repair shop with two
technicians that service an average of 15 vehicles per day.
Previously, Glenmoor leased one solvent sink-top unit that was
used about i hour per week for cleaning parts and was serviced
every 16 weeks. In September 1998, Glenmoor began demonstrat-
ing a small EMC Jetsink aqueous spray cabinet and an EcoClean
Bioflow2o aqueous microbial sink-top unit, and both units provided
positive cleaning results. Glenmoor initially purchased the spray
cabinet and currently uses it to clean about 95 percent of all its
parts. The spray cabinet reduces cleaning labor by as much  as 80
percent. 25 gallons of spent solution (with sludge) is disposed
every six months by a waste disposal company. The remaining 5%
of Glenmoor's parts cleaning are quick cleaning jobs that are per-
formed in the microbial sink-top unit. Although Glenmoor could
perform this small amount of light duty cleaning using rags  or its
aqueous brake washer, they eventually decided to purchase the
microbial sink-top unit for cleaning convenience. The sink-top unit
requires filter replacement about every 6 months and has not gen-
erated any spent solution in over 9 months of continuous use. The
payback period at Glenmoor for replacing solvent cleaning with the
sink-top unit and spray cabinet is 1.8 years. If Glenmoor had imple-
mented only the spray cabinet, the payback period would have
been less than i year. Owner Gary Raver says: "The spray cabinet
cleans parts so well that they shine. Our guys like using both of
these units."
                              Glenmoor Auto Repair use a small, inexpensive spray cabinet which
                              cost them $1,700. They send large parts off-site, for steam cleaning.
                                Selecting the right type of unit for your shop
                                Most shops require more than one type of aqueous unit to
                                meet their cleaning needs. For example, a shop may maintain
                                walk-up microbial sink-top cleaning stations for clean-and-
                                replace operations, as well as a centrally-located spray cabi-
                                net for cleaning heavily soiled or large parts. If the shop ser-
                                vices transmissions or carburetors and does not subcontract
                                the cleaning of these parts, specialized aqueous cleaning
                                units, such as ultrasonic units, are available to meet these
                                special cleaning needs.
                             PARTS CLEANING COSTS COMPARISON
         One Solvent Unit
                  Annual costs
   Leasing, waste
   management 	$690
   Electricity (est.)  	$120
   Cleaning labor  	$2,600

   Total costs	$3,410
   Glenmoor cost summary

   Aqueous Spray Cabinet
               Annual costs
Purchase price
(one-time)	$1,700
Chemicals	$24  .
Solution disposal	$240
Electricity (est.)	$480
Cleaning labor	$494
Total costs	$2,938      Total costs  	$1,834
 Aqueous Microbial Sink-Top
                Annual costs
Purchase price
(one-time)	$1,300
Chemicals	$24 .
Filters	$20
Electricity (est.)	$360
Cleaning labor 	$130
         Total Capital Cost: $3,000  •  Annual Savings: $1,638  • Payback Period = 1.8 Years
"My spray cabinet
cleans parts so well,
they shine."
           —Gary Raver
   Glenmoor Auto Repair
      Fremont, California

-------
          Aqueous Parts Cleaning
                                                                            Best Environmental Practices for Auto Repair
                                             THE DO'S AND DON'TS OF AQUEOUS CLEANING
8
     Dry parts
immediately after
    cleaning to
  prevent rusting
                                                 Demonstrate
                                                 units before
                                                  purchasing
                 Use oil skimming
                     to extend
                    solution life
                              Use filtration to
                            extend solution life
                                                                                             Don't
Don't discharge
waste solution
  into sewers
  Don't contaminate
aqueous solution with
   aerosol solvents
        Don't use solutions with
         greater than 5% VOCs
               Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
              fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regionog/pz/autoneet.
              This fact sheet Is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
                   (publication number EPA-gog-E-gg-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
             (publication number EPA-gog-E-gg-ooz). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention",
                are available at the same phone number for either auto repair (number EPA-9O9-V-99-ooi) or fleet maintenance (number EPA-9O9-V-99-ooa).
                         This fact sheet was produced by the Environmental Protection Agency (EPA) Region 9 pollution prevention program. Mention of trade names, products, or services
                         dots not convey, and should not be interpreted as conveying, official EPA approval, endorsement, or recommendation.

-------
                                                              Case  Studies  in
                             AQUEOUS  PARTS  CLEANING
                                                Best Environmental Practices for Auto Repair Shops • November 1999
                                            Aqueous Cleaning Works!
                                            The case studies featured in this document are from studies conducted in
                                            California between 1997 and 1999. Each of the shops featured in these case
                                            studies successfully switched from solvent to aqueous (water-based) parts
                                            cleaning. These case studies prove that aqueous cleaners are capable of meeting
                                            or exceeding the many parts cleaning challenges encountered in a wide variety
                                            of auto repair operations.

                                            New Environmental Regulations
                                            lead to Improved Aqueous Cleaners
                                            The emergence of a new generation of highly effective cleaning units and
                                            solutions is the direct result of environmental regulations recently passed in
                                            two California air districts. To protect human health and reduce smog, aqueous
                                            parts cleaning solutions are favored or required over solvent cleaners. These
                                            new rules opened the parts cleaning market to new vendors and spurred inno-
                                            vation. Shop owners, facility managers and technicians benefit the most from
                                            the new rules, because compared to solvents, aqueous cleaners:
                                                   COSTLESS  • ARE SAFER TO USE  •  CLEAN EQUALLY WELL
                                            The public also benefits from the overall reduction in volatile organic com-
                                            pounds (VOC) emitted to the air as facilities switch from high VOC solvents to
                                            aqueous cleaners. The estimated VOC reductions as a direct result of enacting
                                            these new rules are 10 tons per day in the Los Angeles area and 2.1 tons per
                                            day in the San Franscisco Bay Area! Widespread use of these new aqueous
                                            cleaners will hopefully bring about similar benefits nationally.
Tips for Successful Conversion
In selecting an aqueous cleaner for your shop, you should test more than one model to identify the model that works best for you.
As the case studies show, often more than one type of unit is needed to fulfill all cleaning needs in a shop (for example, spray cabinet
in combination with microbial sink-top). The good news is; in all but one case featured here, shops are saving significant money by
switching to aqueous cleaning systems. Reduced labor spent cleaning parts account for most of these savings (as with automated spray
cabinets and ultrasonic systems). Savings are also achieved through lower waste disposal costs, because aqueous cleaning solutions
generally last longer than solvent. For more tips on making aqueous cleaning work for you, see the fact sheet entitled "Aqueous Parts
Cleaning, Best Environmental Practices for Auto Repair". It can be obtained by calling (800) 490-9198 or viewed and downloaded at
www.epa.gov/regiono9/p2/autofleet.

-------
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Case Studies in Aqueous Parts Cleaning
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Testing the waters— aqueous parts cleaning case studi
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CASE STUDIES IN AQUEOUS PARTS CLEANING, BEST ENVIRONMENTAL PRACTICES FOR AUTO REPAIR SHOPS
Facility ! Size Operations "Before"
SPECIALTY AUTO REPAIR
*DIesel/Fuel Injection £3 technicians
Specialties |_
Santa Ana, CA ~~
'Newhall Carburetor f;i technician
and Auto Repair f
Newhall, CA |
'Bob's Transmission £3 technicians
and Clutch I
Simi Valley, CA I.
FULL SERVICE AUTO REPAIR
Carry's Autoworks 1 14 bays
,w
L 	 ' 	
'GlenmoorAuto l&bays
Repair §2 technicians

'Auto Electric and Fuel Hj bays
Concord, CA 1 3 technicians
'Corvette Service § full-time technicians,
Company, *:? part-time
Carpentaria, CA ,;": •. • . ,:, ,:::; .';:; • : ' .. : : ' 	 • :; : : : "

Tomvo's -3 technicians
Garden Grove, CA
•
AUTO DEALERSHIPS
'Santa Monica Nissan 18 bays
Santa Monica, CA ^20 technicians

Repairs engines, sensors, i solvent immersion system
and fuel injection systems- serviced every 2 months
i person cleaned parts full-time
Rebuilds carburetors- i solvent carb cleaner tank
i hour cleaning in unit plus 20 serviced every 1.5 months
minutes by hand per carburetor. and i aqueous microbial
20 carburetors cleaned/week .sink-top unit
Repairs and rebuilds 2 solvent sir
transmissions of all kinds .every 1.5 me
1 ''. ','',, 	 ," ''.iwaterjbase
ks serviced
nths and
d spray cabinet


Full Service Shop-
12 hrs/week cleaning parts

Full service shop-
i hour/week cleaning parts

Large cleaning jobs sent to
local steam cleaner

Full service, restoration-
5 hours/week cleaning parts
Full service-
1.5 hours/week cleaning parts


Full service-
33 hours/week cleaning parts
2 solvent sinks serviced
every 1.5 months
i solvent sin
every 4 mori
k serviced
ths
i solvent sink serviced
every 2 months
i solvent sink serviced
every 2 months
i solvent sink
service9 eve'ry 1.5 months
i

7 solvent sinks
serviced every 1.5 months
II
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i ultrasonic system
i ultrasonic system and
i aqueous microbial
sink-top unit
i ultrasonic unit,
i solvent sink and
i aqueous spray cabinet

a microbial sink-top unit
i spray cabinet
i microbial sink-top unit
i spray cabinet
i microbial sink-top unit
i spray cabinet
i immersion
:,: ,,:,

50 gallon spray cabinet
4 leased microbial
sink top units
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-------
r shops
                                                                                 Best Environmental Practices for Auto Repair Shops
»"-•
PS
j New Unit Types

Alpha Cleaning Systems ultrasonic unit
with W.R. Grace cleaning solution
Alpha Cleaning Systems ultrasonic unit
(18 cubic inch) with W.R. Grace cleaning solution,
Zymo microbial unit and solution
Alpha Cleaning Systems ultrasonic unit
with W.R. Grace Daraclean 257 solution

EcoClean Bioflowao, PC solution
EMC Model ioo(used system), ALO jet solution
EcoClean Bioflowio, PC solution
EMC Jetsink, ALO jet solution
EcoClean Bioflow20, PC solution
Landa Model SHs, AX-IT solution
Mirachem w/servicing agreement,
Mirachem 500 solution

EMC spray cabinet, ALO Jet solution
Kleentec Model 4000,
Daraclean 257 solution
P
: Unit Cost

$9.300
$3,000
$5,000

$1,300
$1,600
$1,300
$1,700
$1,300
$4,825
$700

$4,000
$236 per unit
per year
1
'i
;
1
I Annual Savings* j Payback Period

$15,012 jtgjrionths
^.'.
te
$3,412 |ii months
£---
$7,617 |g months
^

$14,874 || months
$1,638 a,8_years
:§£— - .. .-. • ;. . '
3F^ : •
:t2f- • •
$940 pis' years
feV-;.7;-r'..:--'-.--.~'-"
IC^ - .; •:-,_.,_ - . .
ifc»:. :.-.;:_:•,': 	 ;.„,.,•..
ae,,_ _,. . •. ...
$1,021 jf.7 years
t&ssr-'---- - --- , - - -
gjjg-jT- •- •'• -.:-- •••-'•• ••->•>
- ^^::±--^-.-_ - - ; ,^_. "• ; :;i_:^. T;I
$274 pis^years
&s£i~^.^,--:,^., ;.".,-",;-.^^^L»

$10,825 S months
jTL
Testimonial

"The new system saves me time
and money. It can clean fuel
injectors in about 15 minutes
and they look like new"
"1 save a lot of time with this
system. All 1 do is turn the unit
on and I can walk away and do
other things"
"This kind of system is revolution-
ary for cleaning valve bodies. One
day all transmission shops will have
at least one ultrasonic system"

"The spray cabinet has improved
our productivity as well as the
cleanliness of our parts"
"The spray cabinet cleans parts
so well they shine. Our guys like
using both of these units"
"The solution is nice and warm,
much easier on technicians hands
than.solvent.Jhe units meets our
cleaning needs very well"
"Overall we are satisfied with the
spray cabinet. We made this change
because we wanted" to stay in
"compliance and be progressive"
"The Mirachem cleans all the
parts very well and quickly. Our
costs are lower because it does
not need to be changed out as
ibftenis^the SQiyent,tank'' / ,^ "1

"We need a cleaning system that
works well and quickly...the parts
cleaned in the spray cabinet are
cleaned faster and better than
with mineral spirits"
                                    *Annual savings includes cleaning labor, waste disposal, servicing, chemical purchase, and electricity costs.

-------
      1	1  "
                    	II"1!'"
  Case Studies in Aqueous Parts Cleaning
                                                             I                             i i1
                                                  Best Environmental Practices for Auto Repair Shops
   References                                                                                   i
   We gratefully acknowledge the contributions of the following individuals and organizations whose referenced publications contain the
   original source material for this fact sheet:
       :„;' •             '•    ,  ,|          	       ,           '               i       '„• '         j      ,  •    i           '   ':  . 1 i;  , ;
   Water-Based Parts Vfasher Systems: Case Study Conversions prepared for U.S. EPA and Santa Barbara County Air Pollution Control District
   by Michael Morris and Katy Wolf, institute for Research and Techncial Assistance, Pollution Prevention Center, December 11,1998, available
   at http://home.eartnlink.net/~irta/rprtooo2.htm
               liiiiiiiiiiS^^^^^^^^^^^^^                                       "  '  '     	I '"I""    I  j"  '  I'"'	M1  " III' I'l I' 'J j  'I  	'! 	 I I  ' 'J	 '"'"I	I	 "I1 I'l'll"!!"!'  ' 'l "   '
                Repair and Maintenance Cleaning: Case Study Conversions prepared for Southern California Edison by Michael Morris and
   Katy Wolf, Institute 'for Research and Techncial Assistance, Pollution Prevention Center, March 12,1999, available at
   http://home.earthlink.net/~irta/rprtooo3.htm
   'Final Report: Aqueous Cleaning Demonstration Project, City and County of San Francisco prepared for the"cTty~an3 county of San Francisco
   Hazardous Waste Management Program, Administrative Service Department, by Tetra Tech EM Inc., February, 1999. The executive summary
   of the report is available atwww.epa.gov/regiono9/p2/autofleet. The full copy is at www.p2pays.org/ref/o3/o2i97.pdf.
                      1     ii                                                            ii'         I                     i     i   i 'i
   'Finai Report: Aqueous Cleaning Demonstration Project, city and County of Los Angeles prepared for the City of Los Angeles Environmental
   Affairs Department Hazardous and Toxic Materials Office, by Tetra Tech EM Inc., August, 1999. An executive summary of the report is avail-
       *"    *:         J,!,   ','' jjljl'l          II    I ,    ,,                           	 ,,  I '  I '|',|l, ',1,	 ll1	    ,	Jl II  I      I  I, I I I I I Ijj	 ,1 I
   able at vyww,epa.g6v/reg(ono9/p2/autofleet.
   'Aqueous Parts Cleaning, Best Environmental Practices for Fleet Maintenance,  part of this publication  series.
       	I,
     Alpha Cleaning Systems
                                                                                  	i'	|i|imlini	I	
                                                  CASE STUDIES VENDOR CONTACTS
(805) 520-8057, (800) 729-2828     KleenTec
                               (800) 435-5336
      EcoClean Corporation
(510) 797-4050
Landa, Inc.
(408) 998-3051, (800) 547-8672
      EMC
(408) 292-9289,  (562) 908-7696    Mirachem
                                (602) 966-3030, (800) 847-3527
      For Best Cleaning Solutions, Inc.  (225) 334-6990
                                  Safety-Kleen Corporation
                                (800) 344-5191
     Global Sonics
(800) 437-7«7
                                                                       UniKleen
                                (310) 532-0353, (800) 930-4729
      Graymills Corporation
(773) 248-6825
                                                                       W.R. Grace
                                (708) 458-6811, (800) 854-1623
     These vendors were featured In these case studies. Other vendors may provide similar or identical products and services.
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                                                                                                   :;           s;!; .';:  ;; • i;;  ;:       m,
        Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
==^^^
       This fart sheet Is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair1'
       in i   lir^ubilcatio'n number EPA-909-E-99-ooi) or "Trie Pollution Prevention loot Kit, Best Environmental Practices for Fleet Maintenance"'            '
     (publication number EPA-909-E-99-oo2). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention",
         are available at the same phone number for either auto repair (number EPA-909-V-99-ooa) or fleet maintenance (number EPA-909-V-99-002).
             THs fart sheet was produced by the Environmental Protection Agency (EPA) Region 9 pollution prevention program. Mention of trade names, products, or services does not convey, and should not

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                        AQUEOUS  BRAKE
                                  Best Environmental Practices for Auto Repair and Fleet Maintenance • November 1999
Aqueous brake washers perform as effectively as traditional
solvent washers, they are better for the environment, and they
reduce hazardous waste management costs and liability.
             WHAT ARE YOU WAITING FOR?
 If you perform 20 or more brake jobs per month, you can purchase and
 operate an aqueous brake washer and achieve payback in less than 2
 years. This payback threshold was estimated assuming the following:
  • Aerosol brake cleaner = $2 per can
  • Aqueous brake washing unit = $800
  • i can used per brake job
• Aqueous solution = $io/year
• Filters = $zo/year
Costs include purchase only.
                          Which brake washing method
                          is best for the environment?
                          Washing brakes before inspection and repair helps create a
                          clean work area. It also removes dust and debris that prevent
                          the brakes from functioning properly and cause squeaking and
                          grinding. Brake washing can be performed using three devices:
                          •i) aerosol cans of solvent-based brake cleaner, 2) solvent brake
                          washing units, or 3) aqueous brake washing units. The best
                          environmental practice is to use aqueous brake washing units.
                          Aqueous brake washing units use water-based cleaning solu-
                          tions. These solutions are nonflammable and generally less
                          toxic than petroleum-based solvents. Furthermore, aqueous
                          cleaners contain little or no volatile organic compounds (VOCs)
                          that can harm the environment and shop employees. Aqueous
                          brake washing units are widely available and perform as well
                          as solvent-based equipment; however, aqueous brake washers
                          have the following advantages:

                          Advantages of using aqueous brake washers
                          • Little or no solvent vapors or aerosol mists that can be
                           harmful to your workers'health.
                          • Nonflammable.
                          • Do not contribute to smog formation, climate change,
                           or ozone depletion.
                          • No empty aerosol cans discarded as bulky, nonbio-
                           degradable trash.
                          • Reduces overall environmental and safety liabilities
                           for your shop.
                          • Can save you hundreds of dollars per year after
                           payback period.
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          Aqueous Brake Washers
                                                               Best Environmental Practices for Auto Repair and Fleet Maintenance
           How aqueous units work
           Most aqueous brake washing units func-
           tion much like sink-top parts cleaners.
           Aqueous brake washers feature a
           portable basin that can be adjusted to
           fit under the wheel assembly. Units with
           adjustable sink height are preferred by
           most technicians. Compressed air
           pumps the aqueous solution through a
           hose and a flow-though brush. A filter is
           often used to collect debris and keep
           the solution  clean. Aqueous units range
           in cost from $500 to $1,200 to purchase, or $45 to $85 per month
           to lease (lease cost includes waste management).
                                                               Keeping aerosol products
                                                               away from aqueous brake washers
                                                               If you use aerosol brake cleaners to spot clean or
                                                               dry brakes after aqueous brake washing, be aware
                                                               that many aerosol products contain F-listed chemicals. An F-listed
                                                               chemical is a chemical that makes each waste it contaminates a
                                                               hazardous waste, no matter what its concentration in the waste is.
                                                               Even one drop of an F-listed aerosol solvent that drips into your
                                                               brake washing solution is enough to make it a regulated hazardous
                                                               waste! If you must use aerosol products to spot clean, always move
                                                               the aqueous brake washing unit away from the brake area first. To
                                                               save time and avoid potential regulatory problems altogether, use
                                                               compressed air to dry brakes rather than aerosol brake cleaner.
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Managing wastes
When purchased, aqueous brake washing solutions contain propri-
etary compounds that are either nonhazardous or considerably less
hazardous than solvents. With proper filtration and regular addition
of fresh solution to make up for evaporatives losses, many shops
can go for years without requiring solution disposal. Over time
however, contaminants build up creating sludge and making the
solution less effective. Waste solution, sludge and filters may con-
tain metals washed off the brake assembly, or solvents that mistak-
enly dripped into the sink and contaminated the solution. Waste
solution, sludge and filters should be shipped off-site as either
hazardous or non-hazardous wastes. Get  data, or test the waste
stream at least once to make this determination, and dispose of
the waste solution and filters accordingly. Some unit vendors will
dispose of the spent solution for you and  include the cost of this
service in the unit's rental price.
            .-
            Know:
                              An informal survey of San Francisco
                              Bay area shops revealed that aque-
                              ous solution is changed about once
                              every 3 years, on average.
Ask the vendor
How often will I need to change the solution?
How much will it cost to refill the unit?
How often will I need to change the filters?
How should I dispose of solution and filters?
If the vendor recommends dumping solution down the drain or filters
into the trash, ask them to pay for testing the waste solution and fil-
ters to determine proper disposal methods. Aqueous brake washing
wastes (solution and filters) must be disposed of according to state
and local regulations governing sewage treatment and solid and
hazardous waste. In some states, the filters can be recycled.
                                                                             VENDOR CONTACTS FOR AQUEOUS BRAKE WASHERS
                                                                           Clayton Associates
                                   (800) 248-8650
                                                                           Kleer-Flo
                                                                                                  (800) 328-7942
                                                                           Mirachem
                                                                                                  (800) 847-3527
                                                                           Raybestos
                                   (800) 407-9263
 Safety-Kleen
(800) 669-5840
 KleenTec
(800) 435-5336
                                                                           Safe Cleanup Solutions
                                                                                                  (888) 848-0879
                                                                          These vendors provided information for this fact sheet. This list is not
                                                                          complete: other vendors may provide similar or identical products and
                                                                          services.
               Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
              fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/p2/autofleet.
              This fact sheet is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
                   (publication number EPA-gog-E-gg-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
             (publication number EPA-gog-E-gg-ooz). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention"
                are available at the same phone number for either auto repair (number EPA-gog-V-gg-ooi) or fleet maintenance (number EPA-9O9-V-99-ooz).
                    This fact sheet was produced by the Environmental Protection Agency (ERA) Region 9 pollution prevention program. Mention of trade names, products, or services
                    docs not convey, and should not be Interpreted as conveying, official EPA approval, endorsement, or recommendation.

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                             Best Environmental Practices for Auto Repair and Fleet Maintenance • November 1999
                                                       Why recycle antifreeze?
                                                       Dumping waste antifreeze may be illegal: waste antifreeze may
                                                       contain heavy metals such as lead, cadmium, and chromium in
                                                       high enough levels to make it a regulated hazardous waste. A haz-
                                                       ardous waste may never be dumped on land or discharged into a
                                                       sanitary sewer,  storm drain, ditch, dry well or septic system.
                                                       It's Cost-Effective: recycled antifreeze is less expensive than virgin
                                                       antifreeze.
                                                       It Saves Resources: ethylene glycol is produced from natural gas,
                                                       a non-renewable resource.
                                                           Waste antifreeze should be recycled either i) in an on-site
                                                           unit, 2) by a mobile service, or3) off-site.
                                                                          Many sewage treatment agencies respon-
                                                                           sible for wastewater treatment discourage
                                                                           or forbid waste antifreeze disposal into
                                                                           sanitary sewers.
eeze
          WHY BE CONCERNED?
 It is estimated that only 12% of all waste
antifreeze generated in the United States is
recycled each year.
Waste antifreeze should never be disposed of down storm drains or
into surface waters because it causes serious water quality problems
and may harm people, pets or wildlife. Doing so is illegal and punishable
by fines of up to $25,000.
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          Antifreeze Recycling
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Understanding your options
Due to the many on-site and off-site recycling options available,
recycling antifreeze is feasible in all parts of the country. Waste
antifreeze can be recycled by three methods:
i) On-Site Recycling: waste antifreeze is recycled in units pur-
chased by the facility, located on site, and operated by facility
employees.
2) Mobile Recycling Service: a van or truck equipped with a recy-
cling unit visits the facility and recycles waste antifreeze on site.
3) Off-Site Recycling: waste antifreeze is transported to a special-
ized recycling company; these services can also resupply the facili-
ty with recycled antifreeze.
AH waste antifreeze recycling methods involve two steps: i) remov-
ing contaminants either by filtration,  distillation, reverse osmosis,
or ion exchange and 2) restoring critical antifreeze  properties with
additives. Additives typically contain  chemicals that raise and stabi-
lize pH, inhibit rust and corrosion, reduce water scaling, and slow
the breakdown of ethylene glycol.
The type of antifreeze recycling that is best suited to your facility
depends on many factors. The table below summarizes some of
these factors for different antifreeze recycling alternatives.
           Managing recycling wastes
           Antifreeze recycling wastes may be contaminated with metals such
           as lead, chromium, cadmium, copper, or zinc. Depending on the
           type of recycling performed, wastes may include filters, sludge or
           resins. As with all wastes, you should obtain data, or test the
           waste to determine whether it is hazardous and dispose of it
           accordingly. Off-site and some mobile recycling service vendors
           will dispose of the wastes for you. If your vendor manages your
           wastes for you, make sure that proper waste determination and
           disposal is performed.
Using recycled antifreeze

Can I recycle organic acid technology (OAT)
(long-life) coolants?
 In 1999, about 30 percent of new passenger vehicles and 5 percent
of heavy duty equipment were factory filled with OAT coolants.
Many antifreeze recycling units can recycle OAT coolants such as
DexCool™. The most important factor when recycling OAT coolant is
to use a technology that completely removes the "chemistry" from
the waste coolant. Once the coolant has been recycled, it may be
returned to a conventional or OAT coolant or depending on the
additive package  used.
Numerous auto repair and fleet maintenance facilities have used
recycled antifreeze produced from on-site recycling units and
mobile and off-site recycling services for years without experienc-
ing engine damage or other problems as a result. However, there
are a few issues you should be aware of.


Consumer protection and manufacturer warranty issues
As of September,  1999, there is no ASTM quality standard for recy-
cled antifreeze. However, several state agencies, for example
California Weights and Measures, have issued product specifica-
tions for recycled antifreeze. Also, some vehicle manufacturers,
(e.g. General Motors, Ford Motor Company, Detroit Diesel and
Cummins) test and certify antifreeze recycling equipment or have
developed standards for recycled antifreeze.
Because there is currently no single national recycled antifreeze
standard that all recycling methods must achieve, you should
select an antifreeze recycling method after discussing coolant qual-
ity specifications  and vehicle warranty concerns directly with your
recycling unit or service vendors. Some vendors can provide certifi-
cation letters from vehicle manufacturers or state agencies, or will
otherwise guarantee the recycled antifreeze they produce.
COMPARISONS OF ANTIFREEZE RECYCLING METHODS
F On-Site Closed Loop
Common recycling technologies i filtration or
1 ion exchange
Capacity (gallons per hour)
Facility worker training required
Facility disposes of recycling wastes
Capital cost range (1998 dollars)
Cost range per gallon to
recycle antifreeze*
Average labor time required for
coolant change per vehicle (minutes)
4 to 5
yes
yes
$2,500 to $13,800
filtration: $3.00 to $4.50
ion exchange: $4.45 to $7.20
30 to 60
On-Site Batch Mobile Service
filtration j filtration or
or distillation ;• reverse osmosis
4 to 100 ; 55 to 210
yes j no
yes ! some services
$3,700 to $18,000 j None
$0.74 to $4.50 i $1.75 to $3.00
25 to 35 j 20 to 30
Off-Site Service
distillation
375 to 500
no
no
None
$3.20 to $3.70
20 to 30
*Note: Cost ranges are after unit capital cost payback and do not include labor costs. Cost ranges calculated using cost worksheet (see page 3).

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                                                            Best Environmental Practices for Auto Repair and Fleet Maintenance
Cost analysis worksheet for antifreeze recycling


Complete this worksheet, calculate, and compare antifreeze recycling costs. Compare the highlighted rows (rows E, I, N, and GG) to determine

the recycling method with the lowest annual cost. The values provided in the sample column serve only as an example, as.actual costs and savings

will vary according to facility specific conditions. Before beginning, refer to page 4 for preliminary questions you should ask vendors.
BASELINE WASTE ANTIFREEZE GENERATION
A : Gallons of waste antifreeze generated annually
OFF-SITE ANTIFREEZE DISPOSAL
B ; Cost per gallon for disposal
C Gallons of antifreeze (virgin or recycled ) purchased annually
D Cost per gallon to purchase antifreeze (virgin or recycled)
E Total annual cost = (AxB) + (CxD)
OFF-SITE ANTIFREEZE RECYCLING SERVICE
F : Cost per gallon for off-site recycling
G : Gallons of antifreeze (virgin or recycled) purchased annually
H Cost per gallon to purchase antifreeze (virgin or recycled)
1 Total annual cost = (AxF) + (GxH)
MOBILE ANTIFREEZE RECYCLING
J Cost per gallon for mobile recycling
K Gallons of antifreeze (virgin or recycled) purchased annually
L ; Cost per gallon to purchase antifreeze (virgin or recycled)
M Annual waste disposal costs (filters, residual, etc)
N Total annual cost = (AxJ) + (KxL) + M
ON-SITE ANTIFREEZE RECYCLING
General
0 , Gallons of regular (r) or extended life (e) antifreeze (virgin or recycled ) purchased annually
P Cost per gallon to purchase antifreeze (virgin or recycled)
Q Annual antifreeze recycling (number of vehicles or batches)
R ; Average time to recycle antifreeze (one vehicle or batch) in hours
S Annual maintenance and repair costs
Equipment
T Purchase and shipping of recycling unit
U : Unit installation
Additives
V Annual use rate of regular (r) or extended life (e) additives (gallons or packages per year)
W Cost to purchase additives per gallon or per package
Filters
X : Cost to purchase filters
Y Annual filter use rate
Z Annual cost to test filters
Energy
AA Unit voltage (volts)
BB Unit current (amperes)
CC Energy cost (per kilowatt-hour)
DD; Total energy cost [(AAxBB)-r-i,oooxCCxQx R]
Wastes and disposal
EE Annual cost to dispose of recycling wastes (other than antifreeze)
FF Gallons of waste antifreeze generated per year
CALCULATIONS
GG Total annual cost for on-site recycling [(O x P)+S+(VxW)+(XxY)+Z+DD+ EE+(FFx B or F)]
HH On-site unit capital cost (T+U)
11 : Payback period in years for on-site recycling (HH-^annual cost difference). Annual cost difference =
difference in calculated annual cost for on-site recycling (GG) and alternative method (E, 1, or N)
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Antifreeze Recycling
                            Best Environmental Practices for Auto Repair and Fleet Maintenance
                        GETTING STARTED RECYCLING YOUR ANTIFREEZE: QUESTIONS FOR VENDORS
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                   Answers to many of these questions will help you complete the cost analysis worksheet on page 3.
     On-site, mobile, or off-site recycling
     f What types of additives are added to the recycled antifreeze?
     • What is the availability, length, and coverage of the warranty
      on the unit or recycled antifreeze?
     • Is the unit or recycled antifreeze
      certified by any vehicle manufacturers?
     • Can you provide performance
      data about antifreeze recycled
      by this equipment?
     •What wastes are generated
      (fitters, sludge, resin,
      still bottoms)?
     •Who will dispose of the wastes?
     •What is the waste generation rate?
     • Is the waste considered
      hazardous?
     • What is the cost per gallon to
      recycle the antifreeze?
      What does this cost include?
     • What contaminants prevent
      your unit or service from
      recycling antifreeze?
     • Does the technology recycle OAT     On.site> batch ar,tifreeze
      coolants and propylene glycol?      recycling units are
 On-site, closed loop
 antifreeze recycling unit
^flushes the coolant
 system during recycling.
     • Can you provide any references in
      the area who are using your unit
      or service?
 available with filtration
 or distillation recycling
 technology.
Additional questions for on-site equipment vendors
• Does the technology feature filtration, distillation, reverse
 osmosis, or ion exchange?
• Is the on-site unit designed for portable, closed-loop use or
 stationary, batch processing?
• Is the unit powered by electricity or compressed air?
• What voltage or pressure is required to operate the unit?
• How is the unit operated?
• How much operator time is required to operate the unit?
• How much additive is needed per gallon of recycled antifreeze?
• Do you provide additive packages for OAT coolants?
• How much do the additives cost?
• How are the additives obtained?
• Is antifreeze testing required to determine how much additive
 to add or is it fixed?
• What type of antifreeze testing equipment is provided with the
 unit (litmus paper, refractometer, titration kit, other)?
• Will you train our mechanics how to properly use the unit?
• Is a unit available for a short demonstration or trial period?
• What is supplied for the  demonstration?
• Where is the nearest technical sales representative?
• How much does the unit cost?
• Are there any other initial costs such as accessories or special
 additive costs?
• Do you offer lease options; if so, what is the monthly lease cost?
      Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
     fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/p2/autofleet.
     This fact sheet is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
          (publication number EPA-9O9-E-99-ooi) or "The Pollution Prevention Tool Kit, Best EnvironmentalPractices for Fleet Maintenance"
   (publication number EPA-gog-E-gg-ooz). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention",
       are available at the same phone number for either auto repair (number EPA-9O9-V-99-ooi) or fleet maintenance (number EPA-909-V-99-O02).
           ™* facl sheot was P"xluced b'the Environmental Protection Agency (EPA) Region 9 pollution protection.program. Mention of trade names, products, or services
           does not convey, and should not be Interpreted as conveying, official EPA approval, endorsement, or recommendation.

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                   REFILLABLE  SPRAY  BOTTLES
                                 Best Environmental Practices for Auto Repair and Fleet Maintenance • November 1999
            REFILLABLE SPRAY BOTTLES:
     PERCEIVED PROBLEMS AND REAL SOLUTIONS
 Perceived problem

O Refillable spray bottles require
  more labor time because they
  must be refilled.
© Spray nozzles clog.
Real solution

The time needed to refill a
bottle (i to 3 minutes) is
comparable to the time needed
to dispose of an aerosol can
and obtain a new one.

Clogs rarely occur, but when
they do, they can usually be
eliminated by blowing com-
pressed air through both sides
of the spray nozzle. As a preven-
tative measure, technicians
should clear spray nozzles with
compressed air weekly, and keep
dirt and grime out of the bottles
when filling by using funnels
with filters or screens.
© Refillable spray bottle
  are cumbersome.
Bottles the size of typical
aerosol cans are available,
and nozzle extensions can be
attached to larger bottles.
What's wrong with aerosol cans?
When compared to refillable spray bottles, they are expensive
and have greater environmental consequences:
• Ounce for ounce, spray-on product sold in aerosol cans is
 roughly twice the cost of bulk product.
• You pay for propellants in every aerosol can you purchase.
 Most aerosol cans contain 10-15% propellant by weight.
«Carbon dioxide, propane, and butane are commonly used
 aerosol propellants. These are "greenhouse gases" that
 contribute to global warming and smog formation.
• Every year, individual auto repair and fleet maintenance facili-
 ties discard hundreds, and sometimes thousands, of aerosol
 cans used to dispense brake cleaners, carburetor cleaners,
 lubricants and penetrants, engine degreasers, and numerous
 other products as trash, taking up valuable landfill space.
• Used aerosol cans that are not empty may be considered
 hazardous waste by US EPA and many states.
Shops and facilities that switch to refillable spray bottles are
saving money by avoiding the high cost of aerosol cans and
are helping to protect the environment by eliminating the solid
and potentially hazardous waste stream they produce. This
fact sheet is designed to help auto repair shop owners and
fleet managers make informed decisions about implementing
refillable spray bottles.


What are refillable spray bottles?
There are two basic types of refillable spray bottles: i) metal
bottles that spray product using compressed air and 2) plastic
bottles that use a hand pump to spray product. Refillable
metal bottles more closely resemble aerosol cans in terms
of their design and performance. These bottles are filled with
product (for example, brake cleaner) from a bulk container
and are  pressurized with air at 80 to 200 pounds per square
inch using a compressed-air hose. Plastic bottles are also
filled from bulk containers but do not require compressed air.
Instead, they are operated by pumping a trigger to create
a mist or stream of product.
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           Refillable Spray Bottles
O
What to consider when
selecting refillable spray bottles
Capacity. The capacity of air-pressurized, refitlable spray bottles
varies from 7 fluid ounces to i quart. Smaller bottles are useful
for spraying hard-to-reach areas. Larger bottles are more conve-
nient because they require less frequent filling and therefore less
technician time.
Construction material. Refillable spray bottles are available in
different materials and with different finishes (aluminum, stainless-
steel, brass, and steel) for use with different types of bulk product.
Ask the spray bottle manufacturer whether the bottle is compatible
with the product you intend to use.
Nozzte type, i-quart, refillable spray bottles come with standard
spray and stream nozzles. A nozzle that can be adjusted from
stream to spray is also available. Smaller bottles (16- and 8-fluid
ounce) are available that closely resemble the size and shape
of aerosol cans and have a spray pattern similar to an aerosol
can spray.
Nozzle extensions. Nozzle extensions up to 12 inches long
are available for spraying  areas that are otherwise difficult or
impossible to reach.
Cost. Air-pressurized, refillable spray bottles cost from $25 to
$60  each, depending on the construction material.  Chemically
resistant plastic bottles and hand pumps cost from $1 to $6 each.
Be sure to check with the product vendor about plastics that are
compatible with their chemical product.
           Recycle used aerosol cans
           • Under the federal Resource Conservation and Recovery Act
            (RCRA), aerosol cans may be recycled if they have been
            emptied through normal use or punctured and drained to
            remove significant liquids.
           • Some states such as California have more stringent regula-
            tions than RCRA. Be sure to investigate state regulations
            before recycling aerosol cans.
           • Shops are responsible for properly managing any captured
            wastes recovered from puncturing and draining.
Economy. Ounce for ounce, bulk product is cheaper than aerosol
cans. Most common spray-on products are available in containers
ranging in size from i to 55 gallons. You may be able to obtain free
refillable spray bottles from your vendor when you purchase their
product.


Maximizing benefits
Refillable spray bottles do work and can reduce costs—if they are
used correctly. Therefore, be sure to:
• Avoid product losses due to spills during refilling. Use funnels and
 pumps to minimize spills (see next page for details).
• Keep replacement parts on hand. Small, inexpensive parts such as
 nozzle seals, filler caps, valves, and nozzles may deteriorate with
 repeated use and pressurization.
. Refillable spray bottles will be used if they are as convenient
 for workers as aerosol cans; therefore, provide every technician
 with a refillable spray bottle for each type of frequently used
 aerosol product.
«Water in the shop air lines may cause corrosion in some steel refill-
 able spray bottles. Ensure that your shop air supply has a water
 removal device.
                                                                   Many shops stock and
                                                                   use more types and brands
                                                                   of aerosol products than
                                                                   necessary. Use of refill-
                                                                   able spray bottles helps
                                                                   reduce excess inventory.

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                                                                Best Environmental Practices for Auto Repair and Fleet Maintenance
Case studies:
Cost-effective aerosol can reduction
Three auto repair shops (Nielsen Automotive in San Carlos, CA;
Glenmoor Auto Repair in Fremont, CA; and Salem Boys Auto in
Tempe, AZ) and one fleet maintenance facility (City of Sunnyvale,
CA) contributed information regarding their use of pressurized,
refillable spray bottles. This information is summarized below.
Very few implementation problems occurred at the shops. One
shop had problems with minor spills during bottle refilling. To
prevent such spills, the shop modified a $2.00 hand pump to fit a
i-gallon bulk product container. While the pump eliminated spills;
it increased the refilling time from about i minute to 3 minutes  per
bottle. Another shop also had a nozzle clog, which was corrected
by blowing compressed air through both sides of the nozzle.
Shop owners and fleet managers  noted the following refillable
spray bottle advantages:
Cost Savings. "We reduced our aerosol product costs by 84 percent
for the same brake cleaner by switching to refillable spray bottles
and eliminating aerosol can disposal costs."
Efficiency. "Technician efficiency is improved!
A technician requires about i minute to
refill and pressurize a spray bottle,
which is much less time than it
took to walk to the storeroom to
get a new aerosol can. In addition,
we realized a cost savings by
reducing the time needed to order
and stock aerosol cans."
Ease of Use. "Our technicians find
the refillable spray bottles easier to use than aerosol cans
because the bottles give a more predictable shot of product."
Preferred by Technicians. "Refillable spray bottles work as well as
or better than aerosol cans."
Tip. "I use a part-time student worker to top off bottles two to three
times per week, which further saves technician time."
                                                                                                                                   in

Technicians
Service bays
Aerosol cans
per year
Aerosol can product
cost per gallon
Pressurized,
refillable
spray bottles
Total cost for
refillable bottles
Refilling time
Bulk product
cost per gallon
Annual savings
Payback period
Nielsen Automotive ; Glenmoor Auto Repair
9 : 2
6 ; 8
780 (break cleaner) I 192 (break cleaner)
; 288 (carb cleaner)
; 36 (lubricant)
$15.95 ; $38.90 (brake cleaner)
; $24.32 (carb cleaner)
I $38.89 (lubricant)
4 (i-quart) j 6 (i-quart)
i 3 (lo-ounce)
$200 1 $450
3 minutes j 3 minutes
$9-89 i $15.60 (brake cleaner)
I $18.20 (carb cleaner)
; $23.80 (lubricant)
$484 j $926 (brake cleaner)
i $490 (carb cleaner)
i $45 (lubricant)
5 months i 4 months (overall)
Salem Boys Auto
10 tO 12
20
1,560 (brake cleaner)
540 (carb cleaner)
$16.54 (brake cleaner)
$15.45 (carb cleaner)
30 (i-quart)
$o (free .for purchasing
bulk product)
i minute
$6.36 (brake cleaner)
$7.54 (carb cleaner)
$1,570 (brake cleaner)
$465 (carb cleaner)
immediate for both
City of Sunnyvale
10
12
260 (brake cleaner)
$32.96
10 (i-quart)
$400
i minute
$14.00
$1,654
3 months

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              Relillable Spray Bottles
Best Environmental Practices for Auto Repair and Fleet Maintenance
   iu
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 4
              Cost savings and payback
              Use the worksheet below to evaluate refutable spray bottle costs and potential savings for your facility. The worksheet does not include
              the technician time to refill spray bottles because it is usually comparable to the time required to throw away an aerosol can and obtain a
              new one. This worksheet should be completed for each type of aerosol can product that might be replaced by refutable spray bottles; that
              is, you should make several copies of the worksheet and use one for each product type. The data in the sample column below is from an
              actual shop—it may not be representative of your shop's costs.
AEROSOL CAN USE
A Number of aerosol cans used annually
B Fluid ounces per aerosol can
C Cost per aerosol can
0 Gallons of liquid aerosol used annually (A x B -H 128 ounces per gallon)
E Annual aerosol can disposal cost
F Total annual aerosol can cost (A x C + E)
SPRAY BOTTLE USE
G Number of refutable spray bottles needed (assume one per mechanic)
H Unit capital cost for spray bottles and accessories
I Bulk product purchase cost per gallon
J Total annual bulk product purchase cost (D x 1)
RESULTS OF SPRAY BOTTLE USE
K Capital cost (GxH)
L Annual savings (F - J)
M Payback period (years) (K* L)
your facility ;
3


i


4- _
r ..


!»
r

3i»
1
sample
780
13
$1.62
79
Negligible
$i,26"4
^r-— •-*—
4
$"50
$9.89
$780 .

$200 	 ' 	 [ 	
$484
o:? 	
• ' 	 ' J
—r        Payback threshold
              VENDOR CONTACT INFORMATION
              If you use more than 20 cans of brake cleaner or carburetor cleaner
              per month, you can purchase five refillable spray bottles at $50
              each with a payback of less than i year. This payback threshold
              was determined by assuming the following:
              • a shop uses i3-fluid-ounce aerosol cans at a cost of $2 per can
              • no disposal costs are incurred for aerosol cans
              • bulk product costs $10 per gallon.
 Air-pressurized spray bottles
 Milwaukee Sprayer Mfg. Co. Inc.
 (800) 558-7035
 Hand-pumped spray bottles
 McMaster-Carr
 (732) 329-3200
 Impact Products
 (419) 841-2891
                                                                                  Tolco Corporation
                                                                                  (419) 241-1113
                                                                                                               Bulk product
                                                                                                               Zep Mfg. Company
                                                                                                               (408) 739-3656
                                                                                                               MOC Products Co. Inc.
                                                                                                               (818) 896-2258
                                                                                                               Tiodize Co. Inc.
                                                                                                               (714) 898-4377
                                                                                                               CRC Industries Inc.
                                                                                                               (800) 272-8963
                                 Berryman Products Inc.
                                 (817) 640-2376
                                                                                                                 Gold Eagle Co.
                                                                                                                 (773) 376-4400
                                                                                  These vendors provided information for this fact sheet. This list is not com-
                                                                                  plete: other vendors may provide similar or identical products and services.
                   Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
                   fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/p2/autofleet.
                   This fact sheet is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
                        (publication number EPA-909-E-99-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
                 (publication number EPA-909-E-99-002). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention",
                    are available at the same phone number for either auto repair (number EPA-gog-V-gg-ooi) or fleet maintenance (number EPA-gog-V-gg-ooz).
                        This fart sheet was produced by the Environmental Protection Agency (EPA) Region 9 pollution prevention program. Mention of trade names, products, or services
                 >•*•*£/  docs not convey, and should not be interpreted as conveying, official EPA approval, endorsement, or recommendation.

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                                                        FLOOR   CLEANUP
                           Best Environmental Practices for Auto Repair and Vehicle Fleet Maintenance • November 1999
     SOLVENT
                       OIL
                                     ANTIFREEZE
              TOXIC ORGANICS  AND METALS
                      WASH WATER
                             Why keep a dry shop?
                             The history of wastewater regulations is clear: discharge limits
                             will continue to become more stringent. Minimize the impact
                             of these regulations on your shop by adopting a dry shop goal.
                             A dry shop is a shop that has sealed all its floor drains.
                             Although a loo-percent "dry shop" may not be feasible in your
                             area due to melting snow and ice, the methods and equipment
                             presented in this fact sheet will help you reduce floor wash
                             water volume and contamination. This, in turn, reduces your
                             liabilities, protects the environment and community, and even
                             saves you time and money spent cleaning floors.


                             The  effects of flushing wash
                             water down storm drains
                             Water flows untreated from storm drains directly to creeks,
                             streams, lakes, bays, and oceans. If this water is contaminat-
                             ed, it can harm aquatic life; even soapy water can upset
                             aquatic ecosystems. The Clean Water Act makes it illegal to
                             discharge pollutants to surface waters; violators can face
                             imprisonment and fines of up to $25,000 per day! Storm drain
                             connections to indoor drains or sinks are prohibited in most
                             areas. Storm drains are usually located outside a shop. If
                             you are unsure about the nature of your shop drains, ask the
                             building manager or local sewer authority whether any of
                             the drains are connected to storm water sewers.
    SEPTIC TANK
                           STORM DRAIN
                                                               SANITARY SEWER
Discharges "to septic systems
can cause soil, groundwater and
drinking water contamination,
creating site cleanup liabilities.
Discharges to storm drains flow directly to
surface water, causing water pollution and
aquatic ecosystems damage.
Metals accumulate in sewage treatment sludge, preventing
its beneficial use.
Some contaminants "pass through" and are discharged
to lakes, rivers, bays, and oceans.
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           Floor Cleanup
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           Keeping your shop clean  and safe
           When used together, the following practices and equipment sig-
           nificantly reduce the amount of water needed to clean shop
           floors. Minimizing wastewater generation will reduce environmental
           liability and help your shop stay ahead of tightening regulations.
           • Prevent spills from ever reaching the floor. (See back page
            for equipment.)
           • Stop if there's a drop! Never walk away from a spill. If spills are not
            cleaned up immediately:
             - Workers can slip and fall.
             - Oil, antifreeze, and other spilled material
   can mix and be tracked around your shop and
   into vehicles.
  - You will spend more time and money washing the floor.
• Mechanics should carry rags so that small spills can be wiped
 dry when they occur.
• In case a medium-sized or larger spill occurs, cleanup equipment
 should be well marked. For example, attach red flags to mop buck-
 ets used for spill cleanup so they can be easily located by workers.
 Keep all spills out of sewer drains
• Sweep your floor with a broom every day to prevent unnecessary
 dirt and contaminant buildup.
• Never hose down your work area! This practice generates large
 quantities of contaminated wash water that is discharged to a
 sewer, or worse, is flushed out of the shop to a storm drain.
• If you use  a pressure washer to clean your floors, be sure the wash
 water is disposed of properly. Even if pressure washing is performed
 by a contractor, your shop is responsible for proper management of
 the wash water and can be held liable for its illegal disposal. The
 best way to avoid this liability and the costs associated with pres-
 sure washing is to clean up spills when and where they occur.

Consider sealing your shop floor
Sealing your shop floor with epoxy or other suitable sealant can
be expensive (typical cost for epoxy sealing is $1.50 to $2.00 per
square foot), but there are several benefits. An epoxy-sealed floor:
• Won't absorb spills as a concrete floor does.
• Makes spill cleanup easier. (You can squeegee small spills into
 a dustpan and pour liquid into appropriate drum.)
• Requires less time and water to clean.
• Lasts for years and reduces long-term liability for cleanup of
 a contaminated shop floor and soil below.
• Looks great to customers and workers alike.
                                                                              Always "Stop
                                                                              if there's a drop!"
     Use absorbents wisely
     Pigs, pads, pillows, and mats
          Keep these absorbent devices on-hand to prevent very
          large spills from spreading.
                • After use, wring out the absorbed fluid into
                the proper drum for recycling or disposal, and reuse
         the absorbents.
• Spent absorbent devices must be disposed of properly. This involves
 determining whether the spent absorbent is a hazardous waste.


Floor sweep (grease sweep, "kitty litter," rice hull, etc.)
. These absorbents should be used only when the spill can not
 be cleaned with shop rags or dedicated mops (see next page).
• Restrict the use of these absorbents to cleaning up gasoline,
 solvent, or other hazardous waste chemical spills. Manage these
 contaminated absorbents as hazardous waste.
• Use floor sweep until it no longer absorbs fluids. Recycle used floor
 sweep if possible, or dispose as hazardous waste. Floor sweep can
 be processed to reclaim and recycle absorbed compounds. Ask your
 vendor about recycling opportunities for spent floor sweep.
                                                                                              HYDROPHOBICMOPS
                                                                                         Hydrophobia mops absorb only oil, not water or anti-
                                                                                         freeze. They are available from the following vendors:
                                                                                         CCP in Cleveland, OH (800) 321-1050
                                                                                         Hy-Tec Environmental in Walnut Creek, CA
                                                                                         (800) 336-4499
                                                                                         These vendors provided information for this fact sheet.
                                                                                         This list is not complete: other vendors may provide
                                                                                         similar or identical products and services.
                                                                           customer perception and employee moral
                                                                           "Cleaning up spills when they occur saves us time and money and
                                                                           keeps the shop looking clean, which my customers and workers
                                                                           both appreciate."                                —Larry Moore
                                                                                                                       Larry's Autoworks
                                                                                                                Mountain View, California

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                                          Best Environmental Practices for Auto Repair and Fleet Maintenance
                                                        Use absorbent
                                                        and dispose as
                                                       hazardous waste
                Clean with shop
              rags until floor is dry.
              Do not saturate rags.
If oil is present, mop it up first.
     Use a hydrophobic mop only.
     Restrict back-and-forth movement of
     mop to avoid spreading spill.
                          Transfer
                          to used oil
                          drum for
                          recycling.
                                                 If antifreeze is
                                                 present, mop it up
                                                 now.
                                                  Use a dedicated
                                                  cloth mop only.
                                                         Transfer to
                                                         waste coolant
                                                         drum for
                                                         recycling.
Use rags to dry surface.
     Clean with rags until floor is dry.
        Do not saturate.
                industrial laundry or
                 properly dispose.
                                                        Use a wet mop only if
                                                        necessary for final cleaning.
                                                           Use a mild, non-caustic detergent
                                                                            Dump wash water
                                                                            down a sink or toilet
                                                                            (but check with the local
                                                                            sewage agency first).
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           Floor Cleanup
                                                                  Best Environmental Practices for Auto Repair and Fleet Maintenance
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Spill  prevention equipment
Water troughs for secondary containment
of used oil and waste antifreeze
(available from your local feed store)
• These are the same inexpensive troughs that are used for livestock.
 Fluids can be pumped out for use or recycling.
• Clearly mark all stored materials.
• Inspect troughs daily for leaks.
• Keep troughs clean and dry.

Funnel drum covers
Funnel drum covers are available from Hy-Tec Environmental at
(800) 336-4499, Spill Cleanup Direct at (800) 356-0783, and Todd
Automotive at (800) 467-2750. (These vendors provided informa-
tion for this fact sheet. This list is not complete: other vendors may
provide similar or Identical products and services.)
• These items minimize spills when transferring liquids from
 one container to another.
• They also can be used to drain oil filters.

Bulk, pressurized, overhead fluid delivery
(available from'all major motor oil manufacturers)
• Used for oil changes and lube jobs to reduce spills.
• Allows these jobs to be done more quickly.
• The equipment is often provided by the oil manufacturer
 at no charge.
           You  can make a difference!
           A shop owner or manager must send a clear message to technicians
           about how clean the shop should be kept and how spills should be
           prevented and cleaned up. It's your responsibility to make proper
           spill prevention and floor cleaning top priorities for every technician.
                                                                                                WATE R  TROUGH
                                                                             FUNNEL
                                                                             DRUM  COVER
                                                                                                                    OVERHEAD  FLUID
                                                                                                                    DELIVERY
                                                                                               FURTHER SUGGESTIONS
                                                                    • Regularly maintain your oil/water separator.
                                                                    > Clearly mark all indoor drains.
                                                                    • Stencil "No Dumping" near storm drains.
                                                                    • Change fluids at a location far from sewer connections
                Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
               fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/pz/autofleet.
               This fact sheet is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
                    (publication number EPA-909-E-99-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
             (publication number EPA-9O9-E-99-OO2). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention",
                                                                                                      i
                 are available at the same phone number for either auto repair (number EPA-909-V-99-ooi) or fleet maintenance (number EPA-9O9-V-99-OO2).
                    This fact sheet was produced by the Environmental Protection Agency (EPA) Region 9 pollution prevention program. Mention of trade names, products, or services
                    does not convey, and shoutd not be interpreted as conveying, official EPA approval, endorsement, or recommendation.

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                         OIL/WATER  SEPARATORS
                           Best Environmental Practices for Auto Repair and Fleet Maintenance • November 1999
     Simplified diagram ofOWS operation

WASTE WATER-oil, water and solids
   SLUDGE— dirt, sand, sweepings
Heavier or Lighter Than Water? OWSs treat vehicle
and floor wash water by allowing substances lighter
than water to float and substances heavier than water
to sink. Many OWSs also have baffles, coalescers,
and oil skimmers to speed-up or enhance separation
of these substances.
Why be concerned
about oil/water separators?
Oil/water separators (OWS) can be costly to maintain, and if not prop-
erly managed, can pollute surface and ground water, and lead to costly
violations. Have you taken steps to minimize the effects of your OWS
on your budget and the environment? This fact sheet discusses the
basic operation of OWSs in handling vehicle and floor wash water, and
techniques to improve OWS performance and reduce costs and liabili-
ties. To make sure your OWS works properly, remember:
Eliminate contaminants: Don't rely on the OWS to handle wash
water from fuel, coolant, solvent, oil, or paint spills. Instead, clean
up spills when and where they occur with dry methods (see the
Floor Cleanup fact sheet).
Wash without detergents: Emulsifying cleaning compounds dis-
perse oil in wash water and make OWSs ineffective—oil passes
right through to the sewer. High pressure water or non-emulsifying
cleaners are sufficient for most cleaning applications.
Minimize loading: Minimize the amount of solids and oils that
enter your OWS. The less solids and oils that reach the OWS, the
less frequently sludge and floating oil must be removed from the
OWS and the better it will work. Also, minimize the amount of wash
water reaching the OWS. Excessive water flow can flood an OWS,
forcing wastewater through it too fast to allow separation; the
result: oil and other contaminants pass right through to the sewer.
OWSs should not be used to treat storm water runoff.
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TROUBLE SITUATIONS
Chemicals and spills
reach OWS
Sludge builds up in OWS
Excessive floating oil
accumulates in OWS
Detergents reach OWS
POTENTIAL IMPACT
• Sewer discharge violation
• Sludge requires disposal
as hazardous waste
• OWS is less effective because
solids have less time to settle
• Oil discharged to sewer
during high flow periods
• Oil is emulsified and
flows out of OWS to sewer
REMEDY
• Eliminate floor drains from shop
• Clean up spills when and where they occur
• Use dry cleanup techniques in shop
• Eliminate storm water flow into the OWS using berms or curbs
• Install additional grates and screens on drains
• Use sloping pavement and sediment traps around drains
• Pump out accumulated oil on a regular schedule
• Use oil-only absorbent pads to remove and recycle oil
• Use high-pressure, low-volume sprays for vehicle washing
• Do not use oil-emulsifying cleaning solutions (detergents)
• Wash vehicles and engines less often
                                                                                                        U)
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           Oil/Water Separators
                                                                Best Environmental Practices for Auto Repair and Fleet Maintenance
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How do I keep  oil  and solids out?
• Filter filter filter. The best way to reduce OWS sludge is to keep
 solids out of vehicle and floor wash water. Install progressively finer
 grates and screens over the drains to the OWS inlet in order to
 maximize solids separation:
 - Begin with steel bars spaced  3/4 to i-inch apart at the
   OWS drain inlet
 - Add sequentially finer grates  and screens
   (3/4 and i/4-inch screens or  i/4-inch expanded steel mesh)
 - Finish with reusable absorbent material to remove
   very small particles.
• Use oil-only absorbents to separate and recycle oil from your OWS.
 In some older OWSs,  it is not easy to collect and remove separat-
 ed oil.  If your OWS does not have an oil trough or other oil collec-
 tion device, you can use reusable absorbent pads that absorb
 only oil and grease. Put these pads on the water surface to collect
 floating oil. Once saturated, squeeze the oil from the pads; this oil
 can be managed with your used oil, if the squeezed oil is not cont-
 aminated with hazardous waste (get data on your wash water
 quality or analyze a sample at least once to verify). The squeezed
 absorbent pads can be reused.
• Use microbes to digest oil in  your OWS. Bioremediation is a
 proven technique to minimize the oil content in OWS effluent and
 sludge and to reduce OWS cleanout frequency. Microbes added
 to an OWS break down petroleum products suspended or dis-
 solved In the wastewater, floating oil, or sludge. Facilities using
 bloremediation have  eliminated wastewater violations and have
 reported reducing their sludge petroleum content by more than
 So percent Such reductions can lower the regulatory status of
 OWS sludge, which will affect the required disposal method
 and disposal costs. Bioremediation is typically performed under a
 vendor service contract. Microbes are added to an OWS or inter-
                                                                            ceptor lines on a regular basis to replenish microbe populations.
                                                                            Microbes are nontoxic and completely safe; the main by-products
                                                                            of bioremediation are water and carbon dioxide. Vendor service
                                                                            contracts usually cover all materials and labor; monthly costs
                                                                            range from $75 to $130, depending on the size and contaminant
                                                                            loading of the OWS.
                                                                                          BIOREMEDIATION BENEFITS:
                                                                                • Lower hydrocarbon levels in OWS effluent
                                                                                • Less contaminated sludge and lower volume of sludge
                                                                                • Reduction or elimination of odor
                                                                                      LIMITATIONS OF BIOREMEDIATION:
                                                                                • Microbe populations can be killed by harsh chemicals
                                                                                 or pH levels greater than 8.5; do not use detergents
                                                                                 that are caustic or contain emulsifiers
 Case studies:
Car  Repair and Car Wash
Salem Boys Auto of Tempe, Arizona used sloping pavement, grates, and
screens to minimize OWS loading. These controls, together with biore-
mediation, decreased the sludge cleanout frequency and cost by 75%.

U.S. Postal Service Fleet
Maintenance Facility
The Huntington Beach, California facility used bioremediation to
reduce OWS effluent hydrocarbon concentration by more than 80%.
               Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
              fleet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/p2/autofleet.
              Hits fact sheet is part of a package of fact sheets entitled either "The Pollution Prevention Tool Kit, Best Environmental Practices for Auto Repair"
                   (publication number EPA-9O9-E-99-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
            (publication number EPA-909-E-99-oo2). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention"
                are available at the same phone number for either auto repair (number EPA-go9-V-99-ooi) or fleet maintenance (number EPA-gog-V-gg-ooa).
                     TWs fact sheet was produced by the Environmental Protection Agency (EPA) Region 9 pollution prevention program. Mention of trade names, products, or services
                     does not convey, and should not be interpreted as conveying, official EPA approval, endorsement, or recommendation.

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;ion 9 pollution prevention prog

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