*
 i «
A EPA
                 United States Environmental
                 Protection Agency
Region 9
(WST-i-i)
EPA 9O9-E-99-OO2
November
                 Best Environmental Practices
                 for Fleet Maintenance


                  [Uljii
                 giniBH«iM[i

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                                                                                               November 1999
          PROFIT  THROUGH
         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 WASTE = 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
^
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
Quantify Generator (CESQG)
220 Ibs or 27 gallons
or less per month
Less than 1/2 drum
Just 3 regulations!
(see back page for details)
J

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                                                                                           I
                   BEST ENVIRONMENTAL PRACTICES FOR AUTO REPAIR AND FLEET MAINTENANCE
             ICl
     itetelhe wor
                      your current generator status
                rieet pelow tpjdentify and quantify hazardous wastes now leaving your shop.
	
Process
Parts Washing 	 "
Coolant Changing
Brake Washing
Lubricating and
Spot Cleaning
F|oor Cleaning
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"
.:,'. ib,:1;' ' . / .3 Cleaning Service
Other Processes '
Waste Stream
Waste Solvent *
Waste Antifreeze8
Waste Cansc
Waste Solvent"
Waste Cans c
Used Rags or Paper Towels E
Used Rags or Paper Towels E
Used Absorbent'
Trap or Separator Sludges G
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












i 	
, 	 ::±.:::::±::::::;..:..j
: 	
Disposal
Cost












Z 	 	 	 „,„., 	 , 	 ,,.,., 	 ,...„
-,|li; 	 	 - 	 - 	 -j 	 ;|(| 	
J





   aste Stream Regulatory Guidance for "Traditional" Practices
  Mas,{e solvents;
          .
     ite antifreeze may I
                     !it sludges are generally hazardous unless testing demonstrates otherwise.
                         •.••."-'•.
                     hazardous depending oh its metal concentration. Iri a 1999 federal survey of sampling studies, about half the waste
               Dies
                 )roved to be hazardous wastes. If waste antifreeze is hazardous, you may not discharge it into a sanitary sewer, storm
                   , or septic system.  Some states exempt recycled waste antifreeze from hazardous waste regulations. If you recycle waste
                 a state, do not count it as a hazardous waste. Otherwise, test your waste antifreeze or count it as a hazardous waste.

                         e disposed,,,of,intrasj] or, recycled as scrap metal if they are completely empty. Dispose of used aerosol cans as
                 jftfi^yare not empty and tneir contents are hazardous! Do not count empties as hazardous waste.
 ^^
IB
^ K
lli^
llw^
I|lMuffi
  nt ptaRe wasning solvent is very likely to be a hazardous waste.
   ,*'•-.   ':     .;...
[gig	|21S,,,,and gaper towels are very likely to be a hazardous waste if trley are contaminated with gasoline or solvent, if the solvent product
                               at.a.lSiiP1' grater concentration, the contaminated rags or towels'will be a hazardous waste
                                        . If solvent on rags or towels is not an F-listed chemical, use your knowledge or test the rags
                               arerhazardous. If they are hazardous, it is illegal to dispose of tnem in trash. Have used rags laundered
                              or dispose  of tnem as a hazardous wastel
                                             erally regulated, unless they are also contaminated with hazardous wastes. Some states
                                          absorbehts as hazardous waste, unless recycled in accordance with state lawl  '
             'raPs an° oil/water separators may contain heavy metals or solvents. Test sludges at least once to determine whether they
              .metals, o.r.solYgnts.	
 JNasn water or mop watgLls generally not counted as a hazardous waste. However, if wash or mop water meets the criteria for a hazardous

         may not be placed in a sanitary sewer. For example, washing gasoline into the drain would be illegal disposal of a hazardous waste
        lay i
        iolin
        gasoline is hazardous because of its igmtability and benzene content). Even if it is not hazardous waste, wash or mop water must

   ,,,^g
                              se or its ignita
                              i limiting its oi
                  rge requirements limiting its oil and grease content, etc. Check with your sewering agency for requirements
                  . transmission, ana hydraulic fluids; oil filters; refrigerant from air conditioning systems; and batteries are not addressed

              they are recycled in accordance with state and federal laws, they are not counted as hazardous wastes when determining gen-
                >ur shop does not recycle these materials," follow state laws'

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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.
STEPS: 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
Best Practice
Aqueous Spray Cabinet,
Ultrasonic unit,
Microbial Sink-top,
or Immersion unit
On-site or Off-site Recycling
Aqueous Brake Washing
Refillable Spray Bottles
Spill Prevention and
Dry Cleanup Methods
Other Processes -1
Waste Stream
Waste Filters'
Waste Aqueous Solution1
Sludges or Resins"
Waste Filters1
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 a 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









It!--
t
-•

--==




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.
L 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.
H 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 Snoi
|"l!p!"S>y""i6nerate""iess man 220 pounds per month of hazardous wastes .....
                                                                               ETCqurclTviSTtFie ..... sarrHTwelgnTas w"ater], you bfTfcially

                    Gs nave significantly fewer hazardous waste requirements to comply with and many more waste management options.
                afFpoltution regulations and wastewater discharge rules, a CESQG need comply with only three basic hazardous waste
                l|ll!l|l|l|l|l|iiiip                                                                                                   ...
      "rSIlFfequIrernents:
        jUJnazaraQUsvvastejougenerate;
l',flo,not store,,,,inrore,,tliar!,	2,200 pounds 127
     dous waste on site at any one time;
    Qtirnately use, reuse, or recycle your waste on s te, or ensure
     sry M, .your hazaraous'vvaste	to	onejfthe	following:'
                 ly regulated hazardous waste treatment,
       ej"or disposal facility (rSDF)
         > permitted, licensed, or 'registered
                                           By the state to

         municipal or industrial solid waste
       |ty that legitimately uses, reuses, or recycles the waste
            s yyaste prior to its use, reuse, or recycling
  ]|e: Some states require t
 ^EEBSasBMsnEimw'
                              Ication number or farther restrict-
           I options. Call your state hazardous waste agency for
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).
                               ention Tool Kit is a great resource for our industry. Repair shops can realize significant compliance
                                                                                         "      '.     i	"'  ' "'    	
                                                           rry (Vloore, Past President, Automotive Service Councils of California
                                          I agency has more information about compliance and pollution prevention for auto repair shops an
              te or local government t
          t maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regiono9/p2/autofleet.
                   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"
          ion number EPA;gog-E-g9-oo2). To obtain copies of either package, call (800) 490-9198. Accompanying videos, "Profit Through Prevention"
                              me number for either auto repair (number EPA-9O9-V-99-ooi) or fleet maintenance (number EPA-909-V-99-OO2).

     |J	Tl^Sf f«ct iheel* were |»oduce
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                       AQUEOUS  PARTS  CLEANING
                                               Best Environmental Practices for Fleet Maintenance • November 1999
Myth
O Aqueous cleaning units
  do not clean parts as well
  as solvent units.
Fact
Aqueous spray cabinets and
ultrasonic units can clean even
difficult-to-clean parts such as
wheel bearings.
© Aqueous cleaning units
  cannot clean transmissions
  or carburetors.
Ultrasonic units can effectively
clean transmissions and carbure-
tors, including hidden areas.
© Part rusting is a problem.
O Aqueous cleaning
  is expensive.
0 Aqueous cleaning wastes
  are a hassle to manage.
Rust inhibitors in aqueous
cleaners decrease the chances
of rusting. Rusting can be
further minimized by drying
parts immediately after cleaning.

Most facilities can save money by
i) implementing aqueous spray
cabinets to reduce cleaning labor
and 2) maximizing aqueous solu-
tion life.

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.
• Solvent cleaning units are usually a facility's greatest source
 of hazardous waste.
. 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 organization. Minimize your
costs and regulatory 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 commercially
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 available 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 vehicle mainte-
nance facilities 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. Four types of aqueous cleaning units—microbial sink-top, spray, immersion, and ultrasonics—are
           described below. Each type of unit is designed for specific cleaning applications; therefore, most facilities will likely meet all their cleaning
           needs by implementing more than one type of unit.
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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.
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
           Key Features
           • Solution heated to no to i2o°F
           • Filtering available to remove
            solids
           • Microbes degrade oily
            contaminants
           Advantages
           • Low capital cost relative to
            other aqueous cleaning units
           • Little or no waste solution
           • Does not dry or chap technician's hands
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 19O°F
                                                                • Spray pressures of 40 to 60 pounds per square inch
                                                                • Oil skimming options
                                                                • Solution concentration typically maintained between 10 and 15%
                                                                Advantages
                                                                • Significant reduction in cleaning labor
                                                                • High level of cleaning performance
                                                                • Large cleaning capacities available
                                                                • Lower waste management costs compared to solvent units
          Disadvantages
          • May require more scrubbing effort than solvent
          • Difficult to clean heavy or stubborn soils
          • Keeping microbes alive requires proper worker training
                                                                Disadvantages
                                                                • Moderate to high cost
          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
                                                                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 22o-volt outlet is often required
                                                                • Temperature adjuster helps to optimize cleaning performance
                                                                • Insulated units are more energy efficient
          Cost: $1,000 to $1,500
                                                               Cost: $1,700 to $11,500

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                                                                               Besi Environmental Practices for Fleet Maintenance
Selecting the right type of unit for your facility
Most fleet maintenance facilities require more than one type of aqueous unit to meet their cleaning needs. For example, a facility may main-
tain walk-up sink-top cleaning stations for clean-and-replace operations, as well as a centrally-located spray cabinet for cleaning heavily
soiled or large parts. If the facility services transmissions or carburetors and does not subcontract the cleaning of these parts, the facility
may also require an ultrasonic unit. After converting to aqueous cleaning, most facilities have fewer cleaning units because spray cabinets
and ultrasonic units typically can handle a large number of parts.
immersion units:
When soak option is needed
Immersion units consist of a rectangular, tank filled with aqueous
solution and a removable false bottom. Immersion units give tech-
nicians the option of soaking parts in the aqueous solution below
the false bottom to loosen soils on the parts or manually scrubbing
parts on top of the false bottom, as performed in a sink-top unit.
                                                                Ultrasonic units:
                                                                Clean blind areas
                                                                Ultrasonic units consist of a steel tank filled with an aqueous solu-
                                                                tion and are equipped with transducers along the bottom or sides of
                                                                the tank. The transducers generate high frequency sound waves that
                                                                produce and intense microscopic scrubbing action on parts surfaces,
                                                                including blind holes and interior surface areas.
Applications
• Parts with light to moderate soil buildup
• Small to moderate quantities of parts
• Light- to medium-duty repairs
Applications
• Transmissions, carburetors and other hard-to-clean parts
• Parts with blind holes and hidden surface areas
• Heavy-duty repairs and rebuilding
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Key Features
• Allows soaking of parts
• Solution heated to no to 120°F
• Filter and oil skimming options
• Solution concentration typically maintained between 25 to 30%
                                                                Key Features
                                                                • Transducers generate ultrasonic waves
                                                                • Solution heated to 140 to i8g°F
                                                                • Filter and oil skimming options
Advantages
• Soaking can improve
 cleaning and reduce
 scrubbing time
Disadvantages
• More expensive than
 sink-top units
• May be difficult to clean
 heavy or stubborn soils
Unit Selection Considerations
• Make sure unit is at a comfortable height for your workers
• Greater size allows larger parts to be cleaned
• Workers may react negatively to certain odors
• Unit available in stainless steel or plastic construction
                                                                Advantages
                                                                • Very high performance cleaning
                                                                • Ability to clean hidden areas on parts
                                                                • Significant reductions in
                                                                 cleaning labor
                                                                Disadvantages
                                                                • High cost
                                                                • Some units make a "hissing" noise
                                                                Unit Selection Considerations
                                                                • Greater ultrasonics power provides better cleaning ability
                                                                • A 220-volt outlet is required for some units
                                                                • Greater unit size provides more cleaning capacity
Cost: $1,700 to $3,500
                                                                Cost: $5,000 to $12,000

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          Aqueous Parts Cleaning
o
Maximizing aqueous solution  life
Aqueous cleaning solutions 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 its clean-
ing 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.
                                       Your greatest cost for parts cleaning
                                       is labor. The time your workers
                                       spend cleaning parts is time they
                                       could otherwise use for servicing
           vehicles. Spray cabinets reduce cleaning labor by as much as 75 percent.
 .-
 Know:
             convenience
             "I can put wheel bearings covered in heavy grease in the spray
             cabinet, turn on the machine, and go back to work. When I
             come back and pull out the bearings, they're all dean."
                                                       —Mark Foti
                             MUNI technician, San Francisco, California
Killing your microbes will result in an unpleasant odor, oil
accumulation in your solution, or loss of cleaning performance.
Be sure to keep your microbes alive and happy!


Keeping your microbes alive and well
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 accu-
mulate at the bottom of the solution, decreasing cleaning perfor-
mance, 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 suffo-
cate the microbes and should be skimmed off.

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Aqueous Parts Cleaning
Best Environmental Practices for Fleet Maintenance
Aqueous cleaning cost worksheet for fleet maintenance facilities
Complete this worksheet to calculate the costs of replacing solvent cleaning units with.one or more types of aqueous cleaning units.
Although many facilities may choose to lease aqueous cleaning units, this worksheet uses purchase prices to calculate a payback period.
The sample calculations provided are for a facility with four solvent units that converts to one microbial sink-top, one spray cabinet and one
immersion unit. The microbial sink-top handles 30% of the original workload, the spray cabinet handles 50% and the immersion unit 20%.
The values provided in the sample column serve only as an example, as actual cost and savings will vary according to specific conditions.

     Start here by determining your current costs for solvent cleaning.

A
B
C
D
E
F
G
H
SOLVENT CLEANING (leased units with servicing)
Number of solvent units leased
Current cost per service visit per unit
: Number of times unit serviced per year
; Total annual solvent service cost (A x B x C)
: Loaded hourly labor rate of shop worker
; Total number of cleaning labor hours per week
Total labor cost (ExFxs2)
Total annual cost for solvent cleaning (D + G)
your facility i sample
|, 4
fc- $90
!=:*... '
E_ $9,360
i> $5°
H;'-20"
|£ $52,000
f $61,360 ' J
     If you want to implement one or more microbial sink-top units, continue below. If not, skip to the next section.
CONVERSION TO AQUEOUS MICROBIAL SINK-TOP CLEANING (units purchased)
1 Number of microbial sink-top units to be purchased
J Purchase price plus installation costs per unit
K \ Total capital cost of sink-top units (1 x J)
L Cost per gallon of aqueous cleaner
M Estimated aqueous cleaner use per unit per year in gallons
N Aqueous cleaner purchase cost per unit per year (L x M)
O Cost per replacement filter
P ; Number of replacement filters per unit per year
Q : Total cost for replacement filters per unit (0 x P)
R | Total number of cleaning labor hours per week
S ; Total annual labor cost (E x R x 52)
T : Total sink-top unit operation and maintenance (O&M) cost ([N + Q ] x I]+S)
your facility i sample
f-\ i
F $1,400
t/, $1,400
'S~ $6
!S ; 60
1 .'$360
|- $10
fe 12
t $120
fe 	 6
| $15,600
t $16,080
     If you want to implement one or more aqueous spray cabinets, continue below. If not, skip ahead to the next table.
i CONVERSION TO SPRAY CABINET CLEANING (units purchased)
U i Number of spray cabinets to be purchased
V 1 Purchase price plus installation cost per spray cabinet
W i Total capital cost of spray cabinets = U x V
X I Cost per gallon of aqueous cleaner
Y i Estimated aqueous cleaner use per unit per year in gallons
Z j Aqueous cleaner purchase cost per unit per year = X x Y
AAj Disposal cost per gallon of spent solution (including sludge)
BB.j Gallons of solution per spray cabinet
CC ; Number of solution changes per unit per year
DD j Total cost for spent solution disposal per unit = AAx BB x CC
EE1 Number of cleaning labor hours per week (typically reduced up to 80%)
FF 3 Total annual labor cost = E x EE x 52
GG i Total spray cabinet O&M cost = [(Z + DD) x U] + FF
your facility : example
§::- i
§ $3,500
|i-. $3,500
t- $6
ft,. 240
£;- $1,440
£^$5
1^.65 ,-..

i£ $1,950
-i:' -2
|_ $5,200
L $8,590
  Proceed to side two to calculate costs for converting to immersion, or ultrasonic units, as well as to calculate your potential cost savings.

-------
Aqueous Parts Cleaning
                                        Best Environmental Practices for Fleet Maintenance
         Aqueous cleaning cost worksheet for fleet maintenance facilities, continued
             If you want to implement one or more immersion or ultrasonic units, continue below. If not, skip to the last table.
CONVERSION TO IMMERSION/ULTRASONICS (units purchased)
HH Number of immersion/ultrasonic units to be purchased
II " Purchase price plus installation cost per immersion/ultrasonic unit
JJ ] Total capital cost of immersion/ultrasonic units ^HH x II)
KKj Cost per gallon of aqueous cleaner
LL !; Estimated aqueous cleaner use per unit per year in gallons
Vlftf Aqueous cleaner purchase cost per unit per year (KK x LL)
NN Disposal cost per gallon of spent solution (including sludge)
OO , Gallons of solution per immersion/ultrasonic unit
PP Number of solution changes per unit per year
QC£ Total cost for spent solution disposal (N N x.OO x PP)
RR, Number of cleaning labor hours per week (typically reduced)
SS| Total annual labor cost (E x RR x 52)
TT I Total unit O&M cost » ([MM + QQ] x HH] +SS)
your facility ; sample
:. 1
$2,2OO
; $2,200
I $6 	
^, so 	 ; 	
i $480
: $5 	 ;
j 30
i- 4 ...: 	
: $600
r 4
:- $10,400
j $11,480
             Summarize your calculations below to determine your potential cost savings and payback period.
RESULTS
UU Total capital cost of all units purchased (K + W + JJ)
W? Total annual cost savings (including labor costs) (H— T— GG— TT)
WW Payback period (year) (UU/W)
your facility ; sample
f°" $7,100 "
I $25,210
L 0.3 	 .A
         Sample parts cleaning cost comparisons
         The tables below compare the cost of using an aqueous microbial sink-top unit and a spray cabinet to solvent units.
         These costs are based on actual demonstration results at two fleet maintenance facilities.
                  SOLVENT UNIT VS. MICROBIAL SINK-TOP UNIT
                OnejolventJJnjt
                         Annual costs
          Leasing, waste
          management	$1,908
          Electricity (est.)  	$120
          Cleaning labor
          (239 hrs)  	$11,950
          Total costs	$13*978
One Microbial Sink-Top Unit
              Annual costs
Purchase price
(annualized)1	$266
Chemicals	$365
Filters	$60
Electricity (estimated)  .$360
Solution disposal2	$125
Cleaning labor
(239 hrs)  	$11,950
Total costs	$13,126
                            Annual Savings: $852
           Annualized over a 7 year period at 10 percent interest
           Assumes off-site disposal of 25 gallons of waste solution once per year
                                      TWO SOLVENT UNITS VS. ONE SPRAY CABINET
     Two Solvent Units
              Annual costs
Leasing, waste
management	$3,816
Electricity (estimated). $369
Cleaning labor
(738 hrs)	$36,900
Total costs	$41,085
    One Spray Cabinet
              Annual costs
Purchase price
(annualized)1	$776
Chemicals	$510
Solution and
sludge disposal2	$3,672
Electricity (estimated)$3,ioo
Cleaning labor
(221 hrs)	$11,050
Total costs	$19,108
                                               Annual Savings: $21,977
                               Annualized over a 7 year period at 10 percent interest
                               ' Assumes off-site disposal of 64 gallons of waste solution 6 times per year

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                                                                            Best Environmental Practices for Fleet Maintenance
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, fleet maintenance facilities 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 volume
generated, but will generally be $2 to $4 for a gallon if it is a haz-
ardous waste and $1 to $2  for nonhazardous waste. Unless you
obtain permission from your local sewage treatment agency, do not
discharge waste solution to 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. To eliminate waste solu-
tion disposal, some spray cabinets are available that evaporate the
solution, leaving behind a sludge that requires proper disposal.
Check with state and local regulators for potential permitting issues
associated with evaporation.
Full service lease agreements
Convenience at a cost. Most fleet maintenance facilities enjoy the
hassle-free arrangement of full servicing and waste management
provided by a solvent management company. Although some aque-
ous cleaning vendors offer similar servicing
and waste management
arrangements, 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.
 Servicing requirements are shown below.
SERVICING
REQUIREMENTS
                              TIME TO PERFORM
                              AND FREQUENCY
Add water and chemical

Skim oil
(not on microbial units)
Replace filter

Drain and replace solution
                              For 10 minutes,
                              daily to every 2 weeks
                              For 5 minutes,
                              every 2 weeks to every 2 months
                              For 5 minutes,
                              every 2 weeks to every 2 months
                              i hour, every 2 months to
                              every few years
                                                                 >

                                                                 £
                                                                 en
                                                                 €
                                                                  m
                                                                  V)
Self servicing aqueous cleaning units may be easier than you think!
 .-DidYou'J
 Know;
                           Numerous vendors offer aqueous
                           cleaning equipment Before purchasing
                           a unit, always:
                           Obtain and check references from
vendors to learn about unit performance at other facilities and the
servicing support provided by the vendors. Cleaning performance and
maintenance requirements can vary significantly among different
vendors and units.
Demonstrate aqueous cleaning units and solution before making a
purchase. Most vendors allow facilities to demonstrate units for two
to four weeks.

-------
          Aqueous Parts Cleaning
Q
U)
Case study:
MUNI converts to aqueous cleaning
The City and County of San Francisco Hazardous Waste
Management Program is helping Municipal Railway (MUNI) repair
and maintenance facilities identify cost-effective alternatives to sol-
vent part cleaners. Between February and December 1998,14 differ-
ent aqueous cleaning units were demonstrated at three
MUNI fleet maintenance facilities. Based on the demonstrations,
the following conclusions were drawn:
• All MUNI facilities can convert entirely to aqueous cleaning
 without compromising their cleaning performance.
• Facility cleaning requirements are best met by implementing
 two or more types of aqueous cleaning units.
• Significant cost savings can be realized with aqueous spray
 cabinets and ultrasonic units because of reduced cleaning labor
 and larger cleaning capacities. These cost savings can offset
 unit capital costs and result in short payback periods.
• MUNI can  reduce the total number of cleaning units used by
 implementing spray cabinets and ultrasonic units because
 these units have large cleaning capacities.
MUNI is considering the following vendors for full implementation
of aqueous cleaning:
• Ultrasonic Units:         • Immersion Units:
  - Alpha                   - KleenTec
  - GlobalSonics            - Mirachem
           • Spray Cabinets:
            -EMC
            * Landa
            - Safety-Kleen
                         • Microbial Sink-Tops:
                           - EcoClean
                           - ForBest
          Electric bus facility
          Operations: Light-duty repair, preventive maintenance
          Number of Solvent Sink-Top Units: 4
          Average Daily Cleaning Labor: 3.7 hours
          The electric bus facility used a microbial sink-top unit and a spray
          cabinet for a 3-month demonstration period.
          • The sink-top unit met most of the facility's cleaning needs for
           small parts.
          • The spray cabinet was used  to clean large parts.
          • Facility workers responded positively to both units.
                                                                                Electric bus facility conversion to aqueous
                                                                                   From
                                                                               (Solvent Units)
                                                                   Total: 4 solvents
            To
      (Aqueous Units)
•••>- 2 microbial sink-top
    (cost: $1,300 per unit)
••>- i spray cabinet
    (cost: $11,4300 per unit)

••>- 3 aqueous
                                                                      Total capital cost: $14,030  Annual savings: $13,250
                                                                                  Payback period: 1.1 years

                                                                The estimated cost savings is largely from the reduced labor from
                                                                the spray cabinet and reduced servicing and waste management
                                                                costs of the microbial sink-top units.

-------
                                                                                Best Environmental Practices for Fleet Maintenance
Diesel bus facility
Operations: Heavy-duty rebuilding and repair
Number of Solvent Sink-Top Units: 13
Average Daily Cleaning Labor: 18 hours
The diesel bus facility demonstrated three spray cabinets, two
ultrasonic units, one immersion unit, and four sink-top units.
• Facility workers favored the spray cabinets and ultrasonic units
  because these types of units were able to clean almost all
  parts, including heavily soiled parts, while significantly reducing
  cleaning labor.
• One spray cabinet received an extremely positive response
  because of its i) exceptional cleaning performance, 2) automatic
  water fill feature to make up for evaporative losses, and 3) timer
  that automatically reduces solution temperature overnight and
  returns it to the optimal level in the morning.
• The ultrasonic units impressed workers with their ability to clean
  interior surfaces and hidden areas on complex parts, including
  transmissions. However, some workers objected to a constant
  hissing noise made by some units.
• The sink-top and immersion units were used for quick, light-duty
  cleaning of small parts.
• Three of the sink-top units were disliked by facility workers
  inadequate height and sink-top capacity, and poor cleaning
  performance.
       Diesel bus facility conversion to aqueous
    From (Solvent Units)
            8   	
To (Aqueous Units)
3 spray cabinets
(cost: $3,500 per unit)
i ultrasonic
(cost: $12,000 per unit)
3 microbial sink-top
(cost: $1,300 per unit)
2 immersion
(cost: $3,500 per unit)
    Total:  13 solvent  	>-  9 aqueous

   ._ Total capital cost: $33,400  Annual savings: $134,810
                   Payback period: 3 months

 The estimated cost savings is largely from significant reductions
 in cleaning labor from the spray cabinets and ultrasonic unit.
                                                                                                   i!!
                                                                                                   -<
                                                                                                  y
                                less harmful
                                "I like our microbial sink-top unit because I don't have to breath
                                the heavy solvent vapors and its less aggressive on my skin."
                                                                           —Daron Gee
                                                 MUNI technician, San Francisco, California

-------
          Aqueous Parts Cleaning
                                                                                       Best Environmental Practices for Fleet Maintenance
                                             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/autofteet.
              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-9O9-V-99-ooi) or fleet maintenance (number EPA-9O9-V-99-OO2).
                     Tills fact sheet was produced by the Environmental Protection Agency (EPA) Region 9 polution 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.

-------
                                                              Case  Studies  in
                            AQUEOUS  PACTS  CLEANING
                                                Best Environmental Practices for Fleet Maintenance • 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 operations featured in these
                                           case studies successfully switched from solvent to aqueous (water-based)
                                           parts cleaning, or from one brand of aqueous cleaner to another. These case
                                           studies prove that aqueous cleaners are capable of meeting or exceeding the
                                           many parts cleaning challenges encountered in a wide variety of fleet mainte-
                                           nance operations.

                                           New Environmental Regulations
                                           Lead to Improved Aqueous Cleaners
                                           The emergence of a new generation of highly effective cleaning units and solu-
                                           tions 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 operation, 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 fleet (e.g: spray cabinet
in combination with microbial sink-top). The good news is; in all but one case featured here, fleets 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 Best Environmental
Practices fact sheet entitled "Aqueous Parts Cleaning, Best Environmental Practices for Fleet Maintenance". It can be obtained by
calling (800) 490-9198 or viewed and downloaded at www.epa.gov/regionog/pa/autofleet.

-------
ij 	 I! 	 	 |ll 	 ifi 	 1
Case Studies in Aqueous P
Ml I i,
i I
1 i in
i , , ,.,, , ,, ^ i
arts Cleaning
i If '
1 i ' , , : ! !'';i|'. '.' ,
       Testing the waters—aqueous parts cleaning case studies from California vehi
1}
II
III :•.' !•: "'" : 1,1 " ' 	 i •" " i , Vi 	 l.'ll ' i|l', i '• iii
' • :.!i : r
CASE STUDIES IN AQUEOUS PARTS CLEANING, BEST ENVIRONMENTAL PRACTICES FOR FLEET MAINTENANCE OPERATIONS
Facility
JSan Francisco
Municipal Railway
(MUNI) Diesel Bus
Facility-
Woods Heavy Duty
Section



*City of Los Angeles
General Services
Department
7th Street Facility



•City of Los Angeles
World Airport Fleet
Maintenance Facility

'Los Angeles Dept of
Water and Power

I Size i Operations
132 technicians
f (16 per shift)
r
1
a
t
i
E
1
* 40 technicians
r
r
E
t-
s
140 technicians
|,
'*'
|&5 fleet vehicles
f-2 mechanics
| a machinists
ii i
•sj electricians
1
i

Full service-
diesel buses.
18 hours/day cleaning parts



Full service-
Construction equipment,
light trucks, heavy trucks.
140 hours/week cleaning parts



Full service-
automobiles, light trucks,
heavy trucks.
6 hours/week cleaning parts

Full service-
automobiles, light trucks,
heavy trucks. _ja^
5 hours/week /sHm
cleaning parts .^O*H|f 1
"Before"
13 solvent sinks
i
ii
I
1

16 aqueous units:
(All Safety Kleen Units;
3 Model 90 sink-top units,
Mip Model 91 immersion units,
2 Model iiC carburetor
" cleaners,
i Model 81.8 large agitator)

10 aqueous'units:
(All Safety Kleen Units;
6 Model 90 sink-tops,
4 Model 91 immersion units)
i
i
3 solvent sinks;
(2 immersion,
* i sink on a drum)
r \ serviced every 6 weeks
\M^%\

	 • ^=
*^
"After"
4 spray cabinets
l ultrasonic
2 microbial sink-top

i immersion
3 spray cabinets
7 immersion units



i spray cabinet
4 microbial sink-tops
••••.. 	 	 ,=;- '.:» 	 'i' 	 „!'„:
2 non-microbial
sink-top units

1 1' ,
	 	 1
is, ' •', /'! if1

	 i M.IH
	 ; 	 i 	 ;,{,!


-------
intenance facilities
                                                                          Best Environmental Practices for Fleet Maintenance

New Unit Types

EMC Jetsink, ALO Jet solution
Landa SJ-io, Hotsy Tubmate solution
Safety Kleen TLW-2, Aqua Works solution
Global Sonics Grease Monkey Senior,
Brulin 81560 solution
EcoClean Bioflow 20, PC solution
; ForBest IPC36o, Seawash 700 solution
\ Mirachem PW-40S (w/skimmer),
; Mirachem 500 solution

Landa SJ-is, AX-IT solution

i Mirachem PW-40S, Mirachem 500 solution






; Hydroblast Model 50, PowefClean solution
j Mirachem PW-2O, Mirachem 500 solution


i Kleentec Model 4000 Unit,
i Green Unikleen/lPAX solution

Gray Mills Model R35O37A,
Green Unikleen/lPAX solution






Unit Cost

$1,695
$3,900
$3,850
$11,000

$1,295
$1,000
$1,867


$8,190

$3,000






$14,600
$725


$2,200


$2,200


'
:


'
IP ill
Annual Savings* i Payback Period

"rnbriths
E:i, :::- ' ,-'
jjp
|:, •' /
t-' "".•;•"•.-
k~" " ' • .
pf-s ";:. ""',:.',.."
if;:'': •:.-:•••• :v
fen" ' ' '•
fir' :''••-••.• • — •
$203,976 |g months
₯
t
;^_^
t W
it5"
(ST
si
HL
$16,900 SJyear
E
ll:\:; ;,•!:'
IT''- : "
$4,050 j&months
f. '
, '•' ''. . .-.;.- ' ' •
.
™

gv: • • • .-
|y^' '
gl-. --
j 5. • - •
PS:: : • •:"• "•••'• '

Testimonial

"The spray cabinets reduced our
cleaning labor by 8p%"

"The ultrasonic unit is good for
parts with blind passageways"
"the microbial units were good
- for light duty cleaning"
"the immersion unit was good for
parts with baked-on carbon that
could soak for 30 minutes"
"Parts are so clean, they look
like new."

"Cleans very good!"
_
"Chemical does not irritate
my skin"

"Removes grease quite easily"
"I'm impressed"
"Outstanding"
"Works very good"
"Works fine for light duty cleaning"
"It's a good all around cleaner for
pur shpps. We npw use less than
pne can pf aerospl cleaner per month"
"It doesn't take long to save some
money by changing from mineral
spirits to water based cleaning"



•""• -• '• " ' ": 	 " 	 - "j
                                *Annual savings includes cleaning labor, waste disposal, servicing, chemical purchase, and electricity costs.

-------
                                                                                                    •
                                                                                        fjf-llit	li!^^	b^M^L^;	ijj,,^^
                                                                                         Best Environmental Practices for Fleet Maintenanc
        	lit	rt
     Case Studies in Aqueous Parts Cleaning
                        ill	Ill	

       sfei
References
     We gratefully acknowledge the contributions of the following individuals and organizations whose referenced publications contain the origi-
    s'natsource ..... material for this fact sheet:
    ................. ' ....................  ....... — ........ ••• .............. : ......... =  ........ :: .............   i— ......   Sl ..... : ........ -— -.: ......... :: ........ :: ..... s: ............................. : ............ i.:: ............................. i: ......... ' ............. :.. ............ i: ........ :.: ................... ............... : ....... 211 ....... ± ............... : ............ i, ..... ............... :..: ............................. LLI!;;,,! ...... i,::,:,:!;,,!,,, ..... :!:,,,::! ..... ::::!:, giw

                          ,; ..... ............... tjljijij] .................... ;„:; ............... ; ..................... ;„„;; ................................. ; ..... ! .......................................... I ......................... ;,; ........................................ ; ....... ; ................ ..nil,;: ..... i;,:,,: ...... i ..... :,; ...... ! ....... ;; .......... i ....... ;„„; ............... ; I1111;llli;i;ijn:ll;il;!;; .......... ;„! ...... i,;,,:;;,,; ..... ULal,,;,;: ............. i::!,;ii!i^                         ..... „: ,,,,i: ::: ...... i:,:::,;:1 ,„ ,:,::, A::::i!j:i!!i;:: :„ ,!l! li, Ai ' I , / i!!h ij ' i i i i ', ' , i
                                           Cae Study Conversions prepared for U.S. EPA and Santa Barbara County Air Pollution Control District
    1111 at hftp://home.ear
                                                                                                         ,    	!!!!j!jj!!!!!j||fi;!!|»!;!||	|,	i!!!!!!!!!||!!il!i!|lj||!!!!!!!!!!!!!l!!	i	J!i!i'j:i:i!l'!!!;!l!!!l!!!!!!|!!:;	i!!,!!li!!!!l!!!l	    '  	lill!!!ll||li!!l!!ili!Jl!!|il!l!!i!	  I
                                                                                                      i"'	,»ifj" '' '" ''j''''''.!!;!i '|l!;' 'i'|1|liii'ii'''••'•"'(   • ''• «	 i ''l"'"1' "' '"j1'1'1'' ''''''' I
                                                                                   an   ..... for Soutfiern ..... California ' Eel ison 'by Michael ' Morris' and
        yor ntmitefoReseaci aidTenaaAssstance   olution  revenon Center   aren 12 1999 avaaeat
    !!!2!5!!!!!!!! ....... ^ji;|::;:i:;:!::::ii;:::n:!:;i=;;;;;;;:;:;;;;;;;;;;;;;;;;:                                                                                                     ......... "'" ..... <<
     http://home.earthlink.net/~irta/rprtooo3.htm
     'Final Report: Aqueous Cleaning Demonstration Project, City and County of San Francisco prepared for the City ana* County of San Francisco
         j|ii!i|j'       j      'Ki.!|	i|   /i,!:,'!!:}!	/, ":/  ,|:	    ',	   'i i  /'.,' ;	'.i./!	„ *'!„;!„,!,;, „  	:	,,/i*;,,:/..:1 ,1:ij|ji;M!i	.n.;!,!:;,,,:"v;	'	;ii/h«	 ;;:,,,vii;', 	h;.,M	,-:,!,!....;	;i,ir,;f w>^ ,i	Mi;,!1	j	a	i'n I
     Hazardous Waste Management Program, Administrative Service Department, by Tetra Tech EM Inc., February, 1999. The executive summary
         	        ' '     	I'"      |                                                                         I                                         !
     of t^e report  is available at www.epa.gov/regiono9/p2/autofleet. The full copy is at www.p2pays.org/ref/os/02i97.pdf.
         J              ill      'I                                               j i        i       '    i     1                     i          ill
     *flnal 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-
     able at www.epa.gov/regiono9/p2/autofleet.
                         11     |i                                                             i'  |          1                               'i
     'Aqueous Parts Cleaning, Best Environmental Practices for Fleet Maintenance, part of this publication series.
I 1 1 1 1 1 1 1 II II 1 Jd 'l I1 ll
1 1 	 1 III III 1 II 	 __ _ llh 1
'T" ! 'I1'!! I"
CASE STUDIES VENDOR CONTACTS
Alpha Cleaning Systems (805) 520-8057, (800) 729-2828 KleenTec
EcoClean Corporation (510) 797-4050 Landa, Inc.
EMC (408) 292-9289, (562) 908-7696 Mirachem
For Best Cleaning Solutions, Inc. (225) 334-6990 Safety-Kleen Corporation
Global Sonks (800) 437-7117 UniKleen
(800) 435-5336
(408) 998-3051, (800) 547-8672
(602) 966-3030, (800) 847-3527
(800) 344-5191
(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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           Your state or local government environmental agency has more information about compliance and pollution prevention for auto repair shops and
          flqet maintenance operations in your state or area. Additional fact sheets and information can be found at www.epa.gov/regionog/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-gog-E-gg-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
        (publication number EPA-oog-E-oo-ooa). 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-ooo-V-QQ-ooi) or fleet maintenance (number EPA-9O9-V-99-OO2).
        &\  \
        ^p  M   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 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
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.
              WHAf 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 solution = $io/year
   • Aqueous brake washing unit = $800  • filters = $2o/year
   • i can used per brake job            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.                                     v
• 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 damping 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
               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-ooa). 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-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 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 •$ 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 bottles
  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 propellents 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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           Refutable Spray Bottles
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What to consider when
selecting refillable spray bottles
Capacity. The capacity of air-pressurized, refillable 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.
Nozzle 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."

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
V 	
Nielsen Automotive
9
6
780 (break cleaner)
$15-95
4 (i-quart)
$200
3 minutes
$9-89
$484
5 months
Glenmoor Auto Repair : Salem Boys Auto
2 i 10 tO 12
8 j 2O
192 (break cleaner) ; 1,560 (brake cleaner)
288 (carb cleaner) ! 540 (carb cleaner)
36 (lubricant) j
$38.90 (brake cleaner) ; $16.54 (brake cleaner)
$24.32 (carb cleaner) i $15.45 (carb cleaner)
$38.89 (lubricant) I
6 (i-quart) - j 30 (i-quart)
3 (lo-ounce) !
$450 • j $o (free for purchasing
j bulk product)
3 minutes j i minute
$15.60 (brake cleaner) i .$6.36 (brake cleaner)
$18.20 (carb cleaner) j $7.54 (carb cleaner)
$23.80 (lubricant) i
$926 (brake cleaner) ; $1,570 (brake cleaner)
$490 (carb cleaner) j $465 (carb cleaner)
$45 (lubricant) 1
4 months (overall) 1 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
                                                                                                                                   2
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           Refutable Spray Bottles
Best Environmental Practices for Auto Repair and Fleet Maintenance
           Cost savings and payback
           Use the worksheet below to evaluate refillable 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 refillable 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.
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AEROSOL CAN USE
A Number of aerosol cans used annually
B Fluid ounces per aerosol can
C Cost per aerosol can
D Gallons of liquid aerosol used annually (A x B + 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 refillable spray bottles needed (assume one per mechanic)
H Unit capital cost for spray bottles and accessories
1 Bulk product purchase cost per gallon
) Total annual bulk product purchase cost (D x 1)
RESULTS OF SPRAY BOTTLE USE
K Capital cost (G x H)
L Annual savings (F-J)
M Payback period (years) (K* L)
your facility















sample
780
13
~ 	 KSS 	 '
79
Negligible
$1,2§4
• 	 : 	
4
_ $50
$9.89
"$780
	
$200
;,
r.::o,4 	 ~
-".. 	 '. 	 !," .' " *'""'J
           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 13-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-9og-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-909-V-99-002).
                     This fact 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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                                            OIL  LIFE  EXTENSION
                                             Best Environmental Practices for Fleet Maintenance  • November 1999
                                                       Why test your engine oil?
                                                       Fleet maintenance facilities generate a tremendous amount of used
                                                       oil from routine engine maintenance. Engine oil changes are typi-
                                                       cally performed according to mileage or calendar schedules that
                                                       are based on average data for a wide variety of vehicles. As a result,
                                                       engine oil changes are often performed more frequently than nec-
                                                       essary. If this is the case at your facility, you are purchasing and
                                                       throwing away more oil than you need to. This fact sheet .describes
                                                       how a testing program can extend engine oil life and thus lower oil
                                                       consumption, reduce used oil generation, and decrease operating
                                                       costs with no risk to your vehicles.
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                                                      Advantages of oil testing

                                                      Resource Conservation. Oil is a nonrenewable resource; oil sup-
                                                      plies are decreasing, which will drive prices higher. By extending
                                                      engine oil life through testing, you can help save this nonrenewable
                                                      resource!
                                                      Source Reduction. Reducing oil change frequency through testing
                                                      reduces used oil generation at the source.
                                                      Cost Savings. Extending oil life reduces oil purchase and disposal
                                                      costs as well as labor spent on changing oil.
                                                      Monitoring Maintenance Practices. After a few tests, you can identify
                                                      trends to verify that routine maintenance is performed adequately.
                                                      Keeping Minor Repairs Minor. Testing provides early warning of
                                                      engine component problems before they become serious, which
                                                      will: i) reduce repair costs, 2) help you anticipate vehicle down
                                                      time, and 3) minimize "hit and miss" disassembly and inspection.
                      ENVIRONMENTAL ISSUES WITH USED OIL
0 2.7 billion gallons of oil is sold annually in the U.S.
© 50% of oil is consumed and 50% becomes used oil; 31% of the used oil, or about 420 million gallons,
   is never recycled! Much of it goes into the environment.
@ Used oil is recycled by being burned for energy or re-refined. Burning oil results in air pollution that
   includes sulfur and hydrocarbon emissions.
0 3 to 5% of the used oil that is re-refined ends up as hazardous waste sludge.
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          Oil Lite Extension
          Create an oil life extension  program at your facility
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There are four aspects of a successful, cost-saving oil life extension
program: i) establishing baseline information, 2) conducting
engine oil sampling, 3) testing oil, and 4) evaluating test results.

i) Establishing baseline  information
Documenting the following baseline data for each of your vehicles
provides information that will help you evaluate test results and
make decisions about extending oil life:
• Oil change intervals
• Operating environment
. Recent maintenance or repair work
«Brand and type of oil used
• Vehicle age

2) Conducting engine oil sampling
Engine oil sampling should be performed at regular intervals. Begin
your program by sending samples to an off-site laboratory for testing.
Consider this: Collecting engine oil samples does not require much
extra  labor, particularly if samples are collected during scheduled
preventive maintenance and safety checks. Sampling labor is usually
offset by reductions in oil change labor.
Sampling tips:
• Run the engine, and then sample soon after turning off the engine.
• Collect a sample by i) installing a valve to draw off oil just before
 the filter, 2) withdrawing oil through a narrow hose inserted in
 the dipstick tube, or 3) taking a sample when the oil is changed
 (within 15 minutes of engine shutoff).
• Keep hands out of sample bottles and keep bottles tightly capped
 before and after sampling to minimize foreign contamination.
. Consult oil testing companies for sampling equipment
 and methods.
                   METAL CONTAMINATION AND ITS SOURCES
              Aluminum
              Chromium
              Copper
              Itotj
              lead
                      • Piston or bearing wear
                      a Hydraulic system pumps
                      * Transmission components
                      • Piston rings
                      • Roller bearings in geared compartments
                      • Valve stem wear
                      • Thrust bearing wear
                      • Oil cooler core "leaching"
                     .^Transmission or steering disc wear	
                     .'•Gear, shaft, or liner wear
                      • Bearing wear
3) Testing oil
The following are sources of engine oil contaminants.
• Antifreeze contaminates engine oil through a coolant leak, causing
 bearing damage and piston, ring, and liner wear. The first sign of a
 coolant leak is detection of sodium, potassium, or boron in the oil.
• Metals from engine wear contaminate engine oil (see table below,
 "Metal Contamination and its Sources").
• Fuel contaminates engine oil as a result of faulty injectors and can
 reduce oil lubricating qualities, lower oil viscosity, and lead to bear-
 ing failure. As little as 1% fuel content decreases oil viscosity by 4 to
 6 percent.
• Sand and dirt (silicas) enter engine oil from outside sources and
 cause abrasive wear of engine parts.
• Water contamination of engine oil is usually caused by condensa-
 tion in the crankcase. Large amounts of water contribute to forma-
 tion of metal-corroding acids that can damage pistons, rings, and
 the liner. Oil performance is affected when its water content
 exceeds 0.3  percent.
Selecting test methods: Most fleet maintenance facilities test
engine oil for a variety of contaminants and therefore use more
than one testing method. Common tests for oil life extension
include testing for water, metals, viscosity, antifreeze, and
dielectric constant (see table  on next page, "Engine Oil Testing
Methods at a Glance").
On-site testing: After you see how you can extend oil life based on
the test results, consider purchasing on-site oil analysis equipment
to lower your program costs and significantly reduce your waiting
time for results.
On-site testing reduces the lag time between sampling and deci-
sion-making because test results are obtained almost immediately.
On-site testing equipment ranges from small, hand held units
                                which simply measure dielectric
                                constant, to more complex ana-
                                lyzers that can identify specific
                                contaminants and produce oil
                                quality reports. Hickam Air
                                Force Base in Hawaii used both
                                a LubriSensor and a Computa-
                                tional Systems Inc. (CSI) Model
                                5100 oil analyzer to conduct
                                their oil analysis  program. They
                                found that both provided com-
                                parable results to off-site labo-
                                ratory analysis. The Lubri-Sensor
                                costs about $600 and the CSI
Hand-held oil analyzers give test   5100 costs about $8,000.
results quickly.

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                                                                                   Best Environmental Practices for Fleet Maintenance
                                         ENGINE OIL TESTING METHODS AT A GLANCE
         The following test methods are commonly used to evaluate contaminant levels in oil. Costs vary depending on the level of detail required.
   Method
   Ferrographic analysis
   Spectrometric analysis
  Water detection test
  Viscosity test
  Dielectric constant test
Description
Measures the concentrations of particles in oil caused by engine wear.
Particle type, size, and number indicate the severity of wear.
Measures concentrations of metal contaminants that indicate
excessive engine wear.
                                    Two common water detection tests are the Crackle test and the
                                    FT-IR test. The FT-IR test is more sensitive.
Determines whether oil has (i) thickened due to excessive soot,
oxidation, or coolant contamination or (2) thinned due to improper
combustion or the presence of fuel. Oil viscosity increases over time;
however, a decrease in viscosity is considered more serious.
                                    Measures dielectric constant, which is altered by oil contaminants.
Sample testing cost
at an off-site laboratory
                                                                $1 to $4
                                                                On-site
  ) Evaluating test results
Most testing labs or equipment vendors will provide contaminant
thresholds or action levels for specific test methods to help you
decide when to change your oil. Having good baseline information
is important when establishing fleet-specific action levels. The
following rules of thumb apply to two common tests, the viscosity
and dielectric constant tests:

• Action is needed if viscosity increases more than 20 percent,
 or decreases more than 10 percent, from the baseline.
• Changes in the dielectric constant indicate potential problems
 as follows:

 - A moderate increase indicates the  presence of contaminants
   such as dirt, acids, soot, and  oxidation products.
 - An extreme increase indicates the presence of water, antifreeze,
   or metal  particles: immediate action is needed to
   prevent engine damage.

 - A moderate decrease  indicates the presence of fuel:
   immediate action is needed to prevent engine damage.
Moderate increase
                     Extreme increase
                                          Moderate decrease
                               Making the change!

                               Extending oil change intervals safely—
                               a step-by-step approach
                               i) Select a few vehicles that can be easily monitored.
                               2) Gather vehicle history data such as oil consumption, current oil
                                 change interval, and vehicle driving condition information. Collect
                                 and test oil samples from two consecutive oil changes to establish
                                 baseline conditions.
                               3) If the vehicle baseline data indicates no oil quality problems,
                                 increase the oil change interval by 15 to 25 percent (for example,
                                 if the engine oil is currently changed after 4,000 miles, extend the
                                 change interval to 4,800 miles).
                               4) Test oil at the new change interval (for example, 4,800 miles) for
                                 two consecutive oil changes, and compare the results with the
                                 baseline oil test data.
                               5) If test results at the change interval are favorable, consider extending
                                 the change interval further. If the results are not favorable, reduce
                                 the change interval and repeat the testing.
                                                                                (VENDOR CONTACT INFORMATION
                                                                   LubriSensor (for measuring
                                                                   dielectric constant on site)
                                                                   Northern Technologies Int'l Corp.:
                                                                   (800) 328-2433
                                                                   CSI5100 (for on-site oil analysis)
                                                                   CSI: (423) 675-2110
                                                               For off-site oil sampling and
                                                               Probilizer sampling ports
                                                               Titan Laboratories:
                                                               (800) 848-4826
                                                               Websites
                                                                   For off-site oil analysis
                                                                   for various parameters
                                                               National Oil Recyclers
                                                               Association:
                                                               www.noraoil.com
                                                                   Herguth Laboratories, Inc.:
                                                                   (800) 645-5227
                                                               Oil Analysis.com:
                                                               www.noria.com/index.html
                                                                   These vendors provided information for this fact sheet. This list is not com-
                                                                   plete: other vendors may provide similar or identical products and services.
                                      -t
                                      o
                                      m

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           Oil Life Extension
                                                                                                 Best Environmental Practices for Fleet Maintenance
           Case studies:
           Benefits of oil testing
           Several fleet maintenance facilities (Eielson Air Force Base (AFB) in Alaska; Fort Lupton School District Maintenance Shop in Colorado;
           Hickam AFB in Hawaii; and the Idaho Engineering and Environmental Laboratory (I EEL), a Department of Energy facility) provided information
           about their oil testing programs for this fact sheet. As the following table indicates, each of these facilities realized environmental and
           cost benefits from extending engine oil life through oil testing.

Number of vehicles
Oil testing
-J— Ta*"r-"^"'~ 	 '
Number of
samples per month
Time to sample
per analysis
Parameters
analysis
OH change Interval
•* Used oil disposal
per year 	
Engine oil purchased
Engine wear and tear
	
Estimated
payback period
EIELSON AFB
800 vehicles (heavy
machinery, trucks,
and vans)
On site with CSI
model 5100
Cost: $8,000
40 to 60
i hour to sample
and analyze
Silicas
Iron
Metals
Water
Average oil change
interval tripled
Before: 26,260 gallons
After: 3,400 gallons
Savings: $435
Reduced by 13%
Savings: $26,000
No engines lost due to
oil testing (this is also
attributed to synthetic
oil use)
4 months
j.
FORT LUPTON
SCHOOL DISTRICT
23 buses
Off site by Titan Labs
Cost: $6/sample;
"Probilizer" sampling port
available for fleets
50
5 minutes to collect
one sample
Silicas
Metals
Water
Viscosity
Percent fuel
Percent antifreeze
Before: 4,000 miles
After: 8,000 miles
Reduced by 80 gallons
Savings: $230
Decreased but not
quantified
Not tracked

7 months
HICKAM AFB
659 vehicles (trucks, vans,
cars, and various other)
On site with
CSI model 5100;
Cost: $8,000
45
30 minutes to sample
and analyze
Silicas
Ferrous materials
Metals
Water
Average oil change
interval doubled
Before: 2,385 gallons
After: 500 gallons
Before: 2,255 galU>ns
After: 495 gallons
Not tracked

About 18 months
IEEL
1,590 vehicles (buses, trucks,
cars, and heavy machinery)
Off site with Herguth Labs
Cost: variable
32
5 toio minutes to
collect one sample
Non-metallic contaminants
Heavy metals
Water
Viscosity
Percent fuel
Percent antifreeze
Interval increased by about
1,000 miles, and labor
decreased
Before: 10,000 gallons
After: 8,500 gallons
Savings: $600
Decreased but not quantified
Saves about 3 engines per year
that cost $6,000 to $25,000
each. Saves the most on bus
engines ($25,000 for a new
engine and $12,000 to rebuild
an old engine) Net savings:
at least $40,000 per year
About i year
•*

UJ
                 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/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-909-E-99-ooi) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
               (publication number EPA-909-E-99-ooa). 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
                       docs not convey, and should not be interpreted as conveying, official EPA approval, endorsement, or recommendation.

-------
                                       REUSABLE  OIL  FILTERS
                                                 Best Environmental Practices for Fleet Maintenance  • November 1999
                                       WIRE CLOTH
                                       FILTER
                                      ADAPTER
                                      PLATE
       ADVANTAGES OF REUSABLE OIL FJLTERS
       Environmental
• Conserve oil, a non-
 renewable resource.--"
• Reduce potential for:
 used oil contaminating
 groundwater, soil, and
 surface water
    Operational
Reduce on-site filter
 inventory
 • Eliminate draining and
  crushing of used filters
-- • Eliminate used filter
    storage and disposal
 What is a reusable oil filter?
 Fleet maintenance facilities generate hundreds of used oil filters
 every year from routine engine maintenance. In doing so, these
 facilities incur costs associated with maintaining filter inventory and
 managing and disposing of used filters. An alternative to conven-
 tional oil filters is reusable oil filters, which can last up to the life of
 the vehicle and eliminate the waste stream created by conventional
 disposable filters. Using reusable oil filters can save your facility
 money and reduce its impact on the environment.
 A reusable oil filter consists of an adapter plate; a canister; and a
 pleated, stainless-steel, wire cloth filter. The wire cloth replaces the
 paper elements in conventional oil filters. Most filter parts last the
 lifetime of the vehicle. In comparison, conventional oil filters must
 be drained and either landfilled or recycled.
 Will the filter fit any engine? Reusable oil filters are made to fit
 most vehicles. The adapter plate  can be changed to accommodate
 different engine types, while the wire cloth filter inserts are often
 the same for vehicles of similar size. Depending on your fleet, you
 can often replace multiple sizes of disposable oil filters with fewer
 replaceable filter inserts. This makes stocking and ordering filters
 easier, saving you time and money.
 How is the filter cleaned? The wire cloth filter is easily removed,
 cleaned in a parts washer and replaced. Some vendors, such as
 PureCycle Filter System (PureCycle), sell machines specifically for
 washing reusable oil filters. The cleaning time ranges from 5 to 15
 minutes, and cleaning is usually performed when the oil is changed.
 How much does the filter cost? Prices for a reusable filter (including
 adapter plate, canister and wire cloth filter) range from $65 to $130
for cars and small trucks and from $120 to  $300 for large  trucks.
What will the payback period be? According to vendors and facili-
ties using reusable oil filters, the payback period ranges  from i.to 3
years, depending on fleet size and oil change cycles. Savings are
achieved by eliminating purchase and disposal costs for conven-
tional oil filters.
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           Reusable Oil Filters
                                                                                                 Best Environmental Practices for Fleet Maintenance
           Case studies:
           Benefits of reusable oil filters
           Two fleet facilities, Barton Sand and Gravel (a sand and gravel carrier in Minnesota) and the City of Walnut Creek, California, provided
           the following information about usjng reusable oil filters. As the tables show, each of these facilities realized environmental and cost
           benefits from reusable oil filters.
r
Fleet Size
111 1 1 1 1 ill 111 1 !
Filters Used
ii::'1:]!!^
Reusable Filter
IJ"i5p!e"men:Et!bn 	
f-iiii 	 • 	 ;i" 	 • 	 !"!"•!"' ! 	 W 	 '*
i '''nil,'.1 ', , I''1' '?!'!' ' "
Cleaning Frequency
Cleaning Methods
	 ; '' 	 ' 	
Previous Costs
for Conventional
Oil Filters
Reusable Oil
! Filter' Costs 	 '
Flyback Period
™_ j^jj^CoYmmSts 	
S'S^liii'lBhi
BARTON SAND & GRAVEL, MN
100 trucks, 40 of which use reusable oil filters
PureCycle oil filters
($169 to $195 each for heavy trucks)
Started by using i reusable filter and
gradually increased to 40
Clean filters during every oil change
(every 6,000 to 10,000 miles or 6 to 7 weeks)
Use a PureCycle washing machine to clean filters;
cleaning takes about 10 minutes
6 oil changes per year x 40 trucks x $10 per filter =
$2,400 per year
Disposal: $80 per drum x 2 drums per month x 12
months per year = $1,920 per year
40 trucks x $180 (average filter) + $700
(washing machine) = $7,900
Less than 2 years
"Our facility saved money by reducing our inventory and
used oil filter disposal costs. The washing machine has
made cleaning the filters a simple task. This product is a
proactive approach to minimizing environmental impacts
i caused by filter disposal."
CITY OF WALNUT CREEK, CA
290 vehicles; reusable filters used in 10 out of 18
police cars
System One Filter Systems oil filters
($80 each for cars)
Started by using i reusable filter and gradually
increased to 10
Clean filters during every oil change
(every 5,000 miles)
Use a Safety-Kleen parts washer to clean filters;
cleaning takes about 5 minutes
12 oil changes per year x 10 cars x
$3.75 per filter = $450 per year
Disposal: Decreased but not quantified
10 cars x $80 = $800
Less than 2 years
"Our facility is helping the environment by prducing
less waste. Reusable oil filters have finer filtration than
conventional oil filters; reusable filters can serve as an
inspection tool because contaminants can be seen on
the wire cloth screen."
-J

^ YEN DOR CONTACT INFORMATION
PureCycle Filter System System One Filter System Racor i Vortex Fluid Filter Technologies
(612)338-1250 (209)687-1955 (209)521-7861 | (888)286-7839
http://www.purecyclefilters.com http://systemifilter.com http://www.parker.com/racor ! http://www.vortexfilter.com
these vendors provided information for this fact sheet. This list is not complete: other vendors may provide similar or identical products and services.
I
o
I
                 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/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-go9-E-99-ooa) or "The Pollution Prevention Tool Kit, Best Environmental Practices for Fleet Maintenance"
               (publication number EPA-gog-E-gg-ooa). 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-ooi) or fleet maintenance (number EPA-909-V-99-002).
               Cfe  \  This fact sheet was produced by the Environmental Protection Agency (EPA) Region o 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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                              Best Environmental Practices for Auto Repair and Vehicle Fleet Maintenance  • November 1999
      SOLVENT
                          OIL
                                         ANTIFREEZE
                TOXIC ORGANICSlAND 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.
  • OH, 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.
                                                                                               HYDROPHOBIC MOPS
                                                                                        I Hydrophobia mops absorb only oil, not water or anti-
                                                                                        I 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
                                                                                                   ii             Mountain View, California

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                                           Best Environmental Practices for Auto Repair and Fleet Maintenance
                                                         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
ui
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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.
                                                                            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/autoneet.
                This fact sheet Is part of a package of fart 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-gog-E-gg-ooa). 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-ooi) or fleet maintenance (number EPA-909-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
            L S>tj2-/-  does not convey, and should 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.
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
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           Oil/Water Separators
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 feet 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
 bioremediation have eliminated wastewater violations and have
 reported reducing their sludge petroleum content by more than
 80 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-
                                                                                        I                            "'
                                                                Best Environmental Practices for Auto Repair and Fleet Maintenance
                                                                            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.
                                                                                          BlOREMEDIATION 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%.
                        I
               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/regionfl9/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-gp-ooa). 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-ooz).
                   (I  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 should not be interpreted as conveying, official EPA approval, endorsement, or recommendation.

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                          ANTIFREEZE  RECYCLING
                          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, or 3) off-site.
                                                              Many sewage treatment agencies respon-
                                                               sible for wastewater treatment discourage
                                                               or forbid waste antifreeze disposal into
                                                               sanitary sewers.
 'Metafi
Bate
ffreezel
          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
  .
O
SS
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:
l) 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.
All 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 gtycol.
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.
                        i
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.
r COMPARISONS OF ANTIFREEZE RECYCLING METHODS ]

Common recycling technologies
r IBM'11 'i1' 	 •' 	 •• 	 i'!:!1?!11" » 	 iiiiiiijp1 	 Bin11:1: 	 !>ji 	
Capacity (gallons per hour)
Facility worker training required
Facility disposes of recycling wastes
gj^jj -ggj — ~ g^g dollars)
C&st range per gallon to
recycle antifreeze*
.Jljjgjrage ia'Bor time required for
• 	 cSSIant change per vehicle (minutes)
•• • • •• 	 I 	
| On-Site Closed Loop i On-Site Batch
filtration or i filtration
ion exchange ! or distillation
4 to 5 ! 4 to 100
yes : yes
yes ! yes
$2,500 to $13,800 i $3,700 to $18,000
filtration: $3.00 to $4.50 j $0.74 to $4.50
ion exchange: $4.45 to $7.20 j
30 to 60 j 25 to 35
Mobile Service
filtration or
reverse osmosis
55 to 210
no
some services
None
$1.75 to $3.00
20 to 30
'"OffSite'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
O 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 i Energy cost (per kilowatt-hour)
DD 1 Total energy cost [(AA x BB) -=-1,000 x CC x Q x 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 [(Ox 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 =
i difference in calculated annual cost for on-site recycling (GG) and alternative method (E, 1, or N)
V :
your facility

your facility




your facility




your facility





your facility
























your facility



sample
- 2,250
sample
T - •
E-- ~" ' 	 '
; —
—
sample
J5.io
-2,250
,,$3-50
$19,350
sample
: $3.29
25
^$3.85/gal
$0
$7,500
sample

378(r) & 452(6)
- $4.7i(r) & $7-48(e)
150 batches
"15 hours per batch
$800

$8,500
$0
^
32gals.(r)&35gals.(e)
. $.25/gal(r)&$.96/gal(e)

= NA
NA
=:NA

~-_ 240
16
- O.12
$1,037 /year

1 $0
75
sample
$7,423
$8,500
•^ 0.7 (off-site vs.
f pn-site recycling)
• j
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           Antifreeze Recycling
                                                               Best Environmental Practices for Auto Repair and Fleet Maintenance
                                   GETTING STARTED RECYCLING YOUR ANTIFREEZE: QUESTIONS FOR VENDORS

Ul
e
                              Answers to many of these questions will help you

                On-site, mobile, or off-site recycling
                * 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
                 certifieo! by any vehicle manufacturers?
                *Can you provide performance
                 data about antifreeze recycled
                 by this equipment?
                •What wastes are generated
                 (filters, 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
 coolants and propyfene glycol?
• Can you provide any references in
 the area who are using your unit
 or service?
On-site, dosed loop
antifreeze recycling unit
flushes the coolant
system during recycling.
                                                    On-site, batch antifreeze
                                                    recycling units are
                                                    available with filtration
                                                    or distillation recycling
                                                    technology.
complete the cost analysis worksheet on page 3.
   	   	if ";. ,'	      	;	
  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?
  ^ g_ _.• p—yV^~ 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/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-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-gog-V-gg-ooi) or fleet maintenance (number EPA-9O9-V-99-oo2).
                     This fact sheet was produced by 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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Uution prevention t

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