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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 ,., , ,,.,., ,...
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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!--
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-
--==
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 unitsmicrobial sink-top, spray, immersion, and ultrasonicsare
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.
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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
-------
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
>
£
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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 '
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Testing the watersaqueous parts cleaning case studies from California vehi
1}
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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
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t-' "".;".-
k~" " ' .
pf-s ";:. ""',:.',.."
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$203,976 |g months
₯
t
;^_^
t W
it5"
(ST
si
HL
$16,900 SJyear
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ll:\:; ;,!:'
IT''- : "
$4,050 j&months
f. '
, '' ''. . .-.;.- ' '
.
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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.
11111IIIIIIIIIIIIIIIIIV^ 11^^
'l III
ill 11 ill in IIP in mi iiiiH
iiiiiiiiiiiii in ii|iiiiiiiii|i mi i iii|ii|iiliiiiiiii|iiiiii|iiiiii I
I i inn i i In i i ml i in h in
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. ||
/if i- f, « - -, ->;/ - ';,.- , y ""- ^-'-'^.v^--;:r/
i:iiiiii., .jihJlifa ;i':iiiillk:l':ilati :] ^ii^^ >. 'ila,' iinl >in,ai.: &» .lih :vAi^!iSi a^ Li1 'feil imii i jji^
-------
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.
o
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o
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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 costsif 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 shopit 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
;,
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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.
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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.
-------
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
-------
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
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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. ;
-------
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 ineffectiveoil 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
in
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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.
-------
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
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Understanding your options
Due to the many on-site and off-site recycling options available,
recycling antifreeze is feasible in all parts of the country. Waste
antifreeze can be recycled by three methods:
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
>
>
O
70
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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_ _. pyV^~ 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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