?/EPA United Slates Environmental Protection Agency Office of Pollution Prevention and Toxics 7408 EPA745-K-94-011 May 1994 EPA's 33/50 Program Company Profile Johnson & Johnson Printed-oo-Recycled .Paper ------- THE 33/50 PROGRAM This Company Profile is part of a series of reports being developed by EPA to highlight the accomplishments of companies participating in the 33/50 Program. The 33/50 Program is an EPA voluntary pollution reduction initiative that promotes reductions in direct environmental releases and offsite transfers of 17 high-priority toxic chemicals. The program derives its name from its overall goals -- an interim goal of a 33% reduction by 1992 and an ultimate goal of a 50% reduction by 1995. The program uses 1988 Toxics Release Inventory (TRJ) reporting as a baseline. In February, 1991, EPA began contacting the parent companies of TRJ facilities that reported using 33/50 Program chemicals since 1988 to request their participation in the 33/50 Program. As of April, 1994, a total of 1,216 companies had elected to participate in the Program, pledging to reduce emissions of the 17 target chemicals by more than 355 million pounds by 1995. Companies are encouraged to set their own reduction targets, which may vary from the Program's national 33% and 50% reduction goals. Company commitments and reduction pledges continue to be received by EPA on a daily basis. The 1992 TRJ data revealed that releases and transfers of 33/50 Program chemicals de- clined by 40% between 1988 and 1992, surpass- ing the Program's 1992 interim reduction goal by more than 100 million pounds. This accomplish- ment, together with evidence from analysis of facilities' projected releases and transfers of the 17 priority chemicals, reported to TRJ under the Pollution Prevention Act, offers strong encourage- ment that the 33/50 Program's ultimate goal of a 50% reduction by 1995 will be achieved. 17 PRIORITY CHEMICALS TARGETED BY THE 33/50 PROGRAM BENZENE CADMIUM & COMPOUNDS CARBON TETRACHLORIDE CHLOROFORM CHROMIUM & COMPOUNDS CYANIDES DICHLOROMETHANE' LEAD & COMPOUNDS MERCURY & COMPOUNDS METHYL ETHYL KETONE METHYL ISOBUTYL KETONE NICKEL & COMPOUNDS TETRACHLOROETHYLENE TOLUENE 1,1,1-TRICHLOROETHANE TRICHLOROETHYLENE XYLENES Also referred to as methylene chloride EPA is committed to recognizing companies for their participation in the 33/50 Program and for the emissions reductions they achieve. The Program issues periodic Progress Reports, in which participating companies are listed and highlighted. In addition, Company Profiles, such as this one, are being prepared to provide more detailed information about companies that have written to EPA describing significant emissions reduction initiatives. Information presented in these profiles is drawn primarily from the company's written 33/50 Program communications and the annual TRJ reports submitted by their facilities (including Pollution Prevention Act data reported to TRJ in Section 8 of Form R). All company communications to EPA regarding the 33/50 Program are available to the public upon request. EPA does not endorse the performance, worker safety, or environmental acceptability of any of the technical options discussed in this Profile. Mention of any product or procedure in this document is for informational purposes only, and does not constitute a recommendation of any such product or procedure, either express or implied, by EPA.. For information on the 33/50 Program, contact the TSCA Hotline at (202) 554-1404 or contact 33/50 Program staff directly by phone at (202) 260-6907 or by mail at Mail Code 7408, Office of Pollution Prevention and Toxics, U.S. EPA, 401 M Street, SW, Washington, D.C. 20460. 33/50 Program Company Profile: Johnson & Johnson ------- Johnson & Johnson Johnson & Johnson reduced releases and transfers of 33/50 Program chemicals by 77% (575,047 pounds) between 1988 and 1992. Most of these reductions were achieved through source reduction activities, such as process redesign to eliminate use of toxic chemicals. I. CORPORATE BACKGROUND Johnson & Johnson is the world's largest health care company, with over 80,000 employees and manufacturing and sales locations in more than 50 countries. The company manufactures toiletries and baby care products, medical supplies, and pharmaceutical products. In the United States, Johnson & Johnson operates six companies that report releases and transfers of 33/50 Program chemicals to TRI. • Johnson & Johnson Consumer Products man- ufactures skin care, toiletries, and wound care products; • Janssen Pharmaceutica and Noramco, Inc. pro- duce pharmaceutical preparations; Johnson & Johnson implemented a Product I Process Development approach that strives to make pollution preven- tion an integral pan of both new and existing manufacturing processes. • Ethicon, Inc., and Johnson & Johnson Ad- vanced Materials manufacture medical prod- ucts and surgical sutures; • Vistakon, Inc. produces contact lenses. Among Johnson & Johnson's more familiar consumer products are Band-Aid™ Brand adhe- sive strips, Tylenol™ pain reliever, and Stayfree™ sanitary protection. Collectively, these six companies operate nine facilities that reported releases and transfers of seven of the 33/50 Program chemicals: chloroform, dichloromethane, methyl ethyl ketone, methyl isobutyl ketone, toluene, l,l,l-trichloroethane,and xyiene. The company releases and transfers of these chemicals totalled 743,880 pounds in 1988. Releases and Transfers of TRI Chemicals by Johnson & Johnson (1000 pounds) 1988 1992 33150 Program Chemicals Chloroform Dichloromethane Methyl ethyl ketone Methyl isobutyl ketone Toluene 1,1,1-Trichloroethane 15 204 23 36 40 91 8 77 5 11 19 24 25 Xylene (mixed isomers) 336 33/50 Program Subtotal* 744 169 Other TRI Chemicals 795 886 Total* 1,538 1,055 ' Columns do not sum to totals due to rounding. Chloroform is used as a carrier solvent in pharmaceutical manufacturing. The remaining six chemicals are solvents which find a wide variety of uses such as cleaning and degreasing metal parts and machinery, as carriers for pressure-sensitive adhesives, and as solvents in processes for manu- facturing products containing polymers. Data for releases and transfers of 33/50 Pro- gram and other TRI chemicals on a company-wide basis are shown at the end of this profile in Table I, while Table II details the same data for selected Johnson & Johnson facilities. II. CORPORATE ENVIRONMENTAL STRATEGY In 1987, Johnson & Johnson released its "Worldwide Statement on the Environment," which made environmental responsibility a mea- sure of performance for management. In 1989, the company implemented a Product/Process Develop- ment approach that strives to make pollution prevention an integral part of both new and exist- ing manufacturing processes. The company's approach is illustrated by its establishment of a worldwide comprehensive goal to reduce releases of toxic chemicals by 90%, when 33/50 Program Company Profile: Johnson & Johnson ------- indexed to production or sales, based on 1987 levels. This is approximately equivalent to a 75% decrease on an absolute scale. The company has also endorsed and adopted the goals of the Montreal Protocol for reducing the use of CFCs and other ozone depleting chemi- cals, and plans to eliminate all uses of these chemicals well in advance of the Protocol's January 1, 1996 elimination date. This reduction pledge specifically includes carbon tetrachloride and 1,1,1- trichloroethane, two of the 33/50 Program's priori- ty chemicals. Johnson & Johnson's 33/50 Program objectives were to implement achievable reductions of releases and transfers of 33/50 chemicals as early as possible during the 1988-1995 goal period Johnson & Johnson has demonstrated its commitment to the environment by releasing public communications such as a corporate envi- ronmental report and cooperating with govern- ments and civic groups in the areas in which the company operates facilities to highlight environ- mental issues. III. 33/50 PROGRAM GOALS AND POLLUTION REDUCTION ACTIVITIES Johnson & Johnson's 33/50 Program objectives were to implement achievable reductions of releas- es and transfers of 33/50 chemicals as early as possible during the 1988-1995 goal period. John- son & Johnson has also begun informing its suppliers about its corporate environmental strate- gy and will continue this process in the future. To reduce releases and transfers of 33/50 Pro- gram chemicals, Johnson & Johnson has undertak- en several projects at its various facilities: • Eliminating the use of methyl ethyl ketone, methyl isobutyl ketone, and xylene at the Con- sumer Products plant in North Brunswick, NJ. These chemicals were used in the manufactur- ing process for the company's Band-Aid™ Brand adhesive bandages. Vinyl extrusion and a water-based emulsion have been substituted in the manufacturing process, resulting in a decrease of over 380,000 pounds in releases and transfers of these three 33/50 Program solvents between 1988 and 1992. • Equipment and procedure changes in several processes at the Noramco facility in Wilmington, DE, resulting in a reduction in releases and transfers of dichloromethane and toluene of over 131,000 pounds between 1988 and 1992. These changes include: using dichloromethane and toluene in- stead of water as the seal fluid in liquid ring vacuum pumps on processes that use these two solvents, thereby reducing the previous wastewater transfers of mixed water and process solvent; implementing a leak detection and repair program to reduce fugitive emissions; and, eliminating one product recovery step, further reducingdichloromethane transfers in wastewater. This facility has achieved reductions of 52% in releases and transfers of all 33/50 Program chemicals between 1988 and 1992. • Material substitution at Ethicon plants in Somerville, NJ and San Angelo, TX, as well as the Advanced Materials facility in Gainesville, GA and the Vistakon plant in Jacksonville, FL, resulting in a decrease of over 66,500 pounds (74%) in releases and transfers of 1,1,1-trichloroethane between 1988 and 1992. A biodegradable cleaner was substituted for 1,1,1 -trichloroethane. In addition to these reductions, the company has undertaken source reduction efforts with non- 33/50 Program chemicals, such as the replacement of methanol with water as a carrier agent in the preparation of many pharmaceutical products. IV. PROGRESS TOWARD 33/50 REDUCTION GOALS As a result of its pollution reduction efforts, Johnson & Johnson has recduced releases and transfers of 33/50 Program chemicals by 77% (575,047 pounds) between 1988 and 1992. The largest reductions contributing to this achievement were for xylene and methyl ethyl ketone, which de- 3.1/50 Program Company Profile: Johnson & Johnson ------- creased by 93% and 80% respectively. These reductions were due principally to the conversion of the adhesive carrier to aqueous emulsion in the Band-Aid™ manufacturing process. Releases and transfers of 1,1,1-trichloroethane also fell by 74% (66,580 pounds), in conjunction with the company's goal of eliminating the use of this chemical and other ozone depleting substances. The company remains committed to further reduc- tions in releases and transfers of 33/50 Program chemicals in the future. V. SUMMARY OF JOHNSON & JOHNSON'S EXPERIENCE Johnson & Johnson has successfully met its 33/50 Program objectives, primarily through imple- mentation of source reduction measures. The company's commitment to further reductions will be achieved through a "continuous improvement" process. Johnson & Johnson has stated that participa- tion in the 33/50 Program has helped significantly in formulating reduction initiatives and in obtain- ing corporate support for their implementation. The requirement of reporting releases and trans- fers of hazardous chemicals to TRI initially made the company aware of the extent of its emissions and off-site transfers. The company began to develop strategies for reducing releases and trans- fers of hazardous chemicals as figures were first compiled company-wide. The 33/50 Program's Johnson & Johnson's Progress Towards Meeting 33/50 Goals 1600 r 1400 •• 1988 1989 1980 1981 1982 focus on a distinct set of chemicals then helped Johnson & Johnson to develop and choose among specific source reduction projects for the Program's targeted chemicals. 33/50 Program Company Pro/lie: Johnson & Johnson ------- Table I Johnson & Johnson Company Releases and Transfers of TRI Chemicals, 1988-1992 Chemical Chloroform Dichloromethane Methyl ethyl ketone Methyl isobutyl ketone Toluene 1,1,1 -Trichloroethane Xylene (mixed isomers) Year 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 Total Air Emissions (pounds) 14,556 1 1 ,659 8,782 7,902 7,329 46,887 32,867 31,177 33,000 20,000 20,050 22,044 25,268 7,940 4,640 33,371 33,332 32,081 578 1,959 18,567 16,186 16,274 10,904 6,870 71,310 70,332 87,096 60,362 24,000 212,143 189,833 165,331 41,857 24,350 Transfers Percent Off-site Change Transfers for Treatment/ Total Releases 1988-1992 to POTW Disposal/Other and Transfers (1) Total Releases (pounds) (pounds) (pounds) and Transfers 148 0 5 5 5 156,872 1 14,080 137,659 1 10,000 56,000 0 0 0 0 0 0 0 250 5 8,605 21,028 25,256 23,506 18,005 11,005 0 0 0 0 0 3,100 2,700 2,829 130 150 32 0 750 1,178 950 0 0 0 0 1,460 3,048 367 1,426 0 0 3,048 815 1,663 589 475 0 0 0 1,734 1 ,035 19,270 7,580 35 18 0 120,450 133,717 98,655 64,180 0 14,736 1 1 ,659 9,537 9,085 8,284 203,759 146,947 168,836 143,000 77,460 23,098 22,411 26,694 7,940 4,640 36,419 34,147 33,994 1,172 1 1 ,039 39,595 41,442 39,780 30,643 18,910 90,580 77,912 87,131 60,380 24,000 335,693 326,250 266,815 106,167 24,500 -44% -62% -80% -70% -52% -74% -93% ------- Table I Johnson & Johnson Company Releases and Transfers of TR1 Chemicals, 1988-1992 Chemical 33/50 Program Chemicals Non 33/50 Program Chemicals (17 chemicals reported) All TR1 Chemicals Year 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 Total Air Emissions (pounds) 416,884 376,253 366,009 162,543 89,148 270,027 244,247 241,644 413,148 410,747 686,911 620,500 607,653 575,691 499,895 Transfers Percent Off-site Change Transfers for Treatment/ Total Releases 1988-1992 toPOTW Disposal/Other and Transfers (1) Total Releases (pounds) (pounds) (pounds) and Transfers 181,148 142,036 164,249 128,145 75,765 373,613 321,960 420,781 340,188 288,541 554,761 463,996 585,030 468,333 364,306 145,848 142,479 102,529 67,699 3,920 150,876 209,356 184,593 237,867 186,536 296,724 351,835 287,122 305,566 190,456 743,880 660,768 632,787 358,387 168,833 -77% 794,516 775,563 847,018 991,203 885,824 11% 1,538,396 1,436,331 1,479,805 1,349,590 1,054,657 -31% Percent Chance from 1988-1992 33/50 Program Chemicals Non 33/50 Program Chemicals All TRI Chemicals -79% 52% -27% -58% -23% -34% -97% 24% -36% -77% 11% -31% Notes: (1) Total Releases and Transfers for 1991 and 1992 do not include on- or off-site recycling or energy recovery. ------- Table II Johnson & Johnson, Selected Facilities Releases and Transfers of TRI Chemicals, 1988-1992 Chemical Total Air Emissions Year (pounds) Transfers Off-site for Transfers Treatment/ Total Releases to POTW Disposal/Other (1) and Transfers (pounds) (pounds) (pounds) Johnson & Johnson Consumer, North Brunswick, NJ Methyl ethyl ketone Methyl isohutyl ketone Xylene (mixed isomers) 33/50 Program Chemicals Noramco of Delaware Inc., Wilmington, Dichloromethane Methyl isohutyl ketone Toluene 33/50 Procram Chemicals 1988 1989 1990 1988 1989 1990 1988 1989 1990 1991 1988 1989 1990 1991 DE 1988 1989 1990 1991 1992 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 18,050 17,942 15,478 33,371 29,914 29,561 208,343 164,783 137,481 14,957 259,764 212,639 182,520 14,957 46,887 32,867 31,177 33,000 20,000 1,600 8,605 5,063 4,635 4,800 1,100 55,492 37,930 35,812 37,800 22,700 0 0 0 0 0 0 0 0 0 0 0 0 0 0 156,872 1 14,080 137,659 110,000 56,000 8,600 19,823 25,006 23,256 18,000 11,000 176,695 139,086 160,915 128,000 86,600 3,048 367 1,426 3,048 815 1,413 120,450 133,717 98,655 64,180 126,546 134,899 101,494 64,180 0 0 0 0 1,460 0 0 0 0 670 180 0 0 0 670 1,640 21,098 18,309 16,904 36,419 30,729 30,974 328,793 298,500 236,136 79,137 386,310 347,538 284,014 79,137 203,759 146,947 168,836 143,000 77,460 10,200 28,428 30,069 27,891 23,470 12,280 232,187 177,016 196,727 166,470 110,940 ------- Table II Johnson & Johnson, Selected Facilities Releases and Transfers of TRI Chemicals, 1988-1992 Chemical Year Ethicon Inc., San Angelo, TX 1,1,1 -Trichloroethane 1988 (Only 33/50 chemical reported) 1989 1990 1991 1992 Total Air Emissions (pounds) 39,460 41,032 37,800 36,000 24,000 Transfers Off-site for Transfers Treatment/ to POTW Disposal/Other ( 1 ) (pounds) (pounds) 0 7,200 0 0 0 0 0 0 0 0 Total Releases and Transfers (pounds) 46,660 41,032 37,800 36,000 24,000 Advanced Materials, Gninseville, GA 1,1,1-Trichloroethane (Only 33/50 chemical reported) Vistakon Inc., Jacksonville. FL 1988 11,600 11,600 1,1,1 -Trichloroethane (Only 33/50 chemical reported) 1988 1989 1990 1991 18,750 24,750 39,750 15,862 0 0 0 0 12,070 7,580 35 18 30,820 32,330 39,785 15,880 Notes: (1) Total Releases and Transfers for 1991 and 1992 do not include on- or off-site recycling or energy recovery. ------- |