United States
         Environmental Protection
         Agency
ORD{RD-681)
Pollution Prevention
Office(PM-219)
EPA Document Number
October 1989
Version 1,0
&EPA   Pollution Prevention
         In Printing and
         Allied  Industries
         Saving Money Through
         Pollution Prevention

-------
      Pollution  Prevention
In Printing and Allied Industries
              DRAFT

          Saving Money
  Through Pollution Prevention
        U.S. Environmental Protection Agency


              October 1989

-------
                                              Preface

       Pollution Prevention in Printing and Allied Industries is intended to provide you with a brief introduction
to pollution prevention, including what it is, how it can put money back into your company's pocket, what
its basic elements are, and where you can get additional assistance.  This booklet also  provides a sample
of the various technical options available to a wide range of printing and allied facilities.  Typical economics
(for example, capital investment, annual  savings, and payback periods) are also provided for many of the
options.

       The technical and economic information in Pollution Prevention in Printing and Allied Industries is
intended to be representative more than comprehensive.  The collection and organization of this information
is an ongoing and evolutionary process.  The first version of this booklet reflects a sampling of information
readily available at the time of preparation. As more pollution prevention activity  takes place and technical
approaches to pollution prevention change, EPA hopes to update and publish follow-up versions of this
booklet.

       Pollution Prevention in Printing and Allied Industires is only one of many sources of pollution prevention
information available to you  from EPA.  For additional  information about pollution prevention, or to
comment on this booklet, call:

               •       The RCRA/Superfund  Hotline,  at  (800) 424-9346, or
                       (202) 382-3000;

               •       Myles Morse, of EPA's  Pollution Prevention  Information
                       Clearinghouse, at (202)  475-7161;  or

               •       James Lounsbury, Director of EPA's Waste Minimization
                       Staff, at (202) 382-4807.

-------
                                     The Purpose of this Booklet

        If your printing and allied industry operations  generate any wastes, the information in this booklet
can help your firm.
                  POLLUTION PREVENTION CAN:
                               Significantly reduce your firm's costs, liabilities, and
                               regulatory burdens associated with waste management; and

                               Enhance your firm's efficiency, product quality, and public
                               image.
                                            Hes
        The United  States Environmental  Protection Agency (EPA) developed this booklet to help your
firm implement a pollution prevention program.  It highlights the various components of a pollution
prevention program.  It also provides two tables to help you  identify specific pollution prevention options,
based on the types of processes or operations at your facility.  The tables contain technical, cost, and waste
reduction information on a  variety of options  that have actually been used at printing and allied facilities.
The information contained  in the tables will  help you evaluate potential annual savings from numerous
pollution prevention techniques.
 PRINTING AND ALLIED PROCESSES INCLUDE:

    •    Preparation
        --  Typesetting
        --  Lithography
        --  Letterpress
        --  Gravure
       '--  Engraving (stationery)
        --  Photoengraving:

    •    Printing              ':.;/•
        --  Heatset Lithography
        --  Non-Heatset Lithography
           -  Thermography
           -  Business Form Printing
           - Sheeted Lithography
        -  Letterpress Printing (including
 •":         flexography)
      —  Gravure  Printing

    •    Finishing Operations
        --  Looseleaf Binding Manufacturing
        --  Trade Binding
        -  Book Binding
        --  In-House Binding
        --  Magazine and Catalog  Binding
        The Information in this Booklet
       Will Be Helpful to Your Company

   This booklet is designed to be  most useful to
firms that engage in printing  operations.   You
should read this booklet if your firm is involved
in printing, or if it is involved in printing-related
processes.

   This booklet will be useful if your facility uses
any  materials  resulting in  the  generation  of
hazardous or non-hazardous wastes.   Table I
identifies many of the materials typically used by
printing and  allied  facilities  and Table II shows
what many of these facilities have done to save
money.
                   a

-------
      Your Company Can Save Money by
      Minimizing the Waste it Generates

   In addition to  relying on  traditional  waste
management approaches (such as treating or dis-
posing of waste after it has been generated), many
facility managers  are finding that by minimizing
the amount of waste their  operations generate
they can actually  improve their firm's "bottom
line."
 POLLUTION PREVENTION REDUCES:

     • Aggregate costs for raw materials
     • Treatment/disposal costs
     • Environmental liability and fines
   In addition  to  these economic incentives for
pollution prevention, EPA is taking several steps
to create additional incentives for firms to reduce
their waste generation.  Some  of EPA's actions
include:

•  Making technical information available to
   help firms identify ways of reducing waste
   generation.

•  Supporting  the  development  of  State
   programs  to assist  firms in  their waste
   reduction  efforts.

•  Requiring   hazardous  waste   generators,
   under  the  Resource  Conservation  and
   Recovery Act (RCRA), to certify on their
   hazardous  waste  manifests  and  annual
   permit reports  that they  have a "program-
   in-place" to  reduce the volume or quantity
   and  toxicity of their hazardous wastes as
   much as economically  practical.

•  Requiring generators to  describe on their
   RCRA biennial  reports  the  efforts  they
   have undertaken during the  year to reduce
   the volume  and toxicity of their hazardous
   waste, and  to  compare  these efforts to
   previous years.
        What is "Pollution Prevention?"

   Pollution prevention emphasizes reducing or
eliminating  any  releases  of hazardous materials
(including hazardous wastes) into the environment
through   the  use   of  source  reduction   and
environmentally-sound  recycling.   A  pollution
prevention program can  be developed  by any
business  that  generates  wastes.   The program
might include several elements intended to reduce,
to the extent feasible, any air or water  discharges,
or any solid or hazardous waste that is generated
at the facility.
                                                                             DRAFT
   Source reduction is intended to minimize or
eliminate  the waste at its source, before it  is
generated or released.  Recycling, on the other
hand, focuses on the use, reuse, or reclamation of
the  waste  as  an  effective  substitute  for  a
commercial  product  or  as  an  ingredient  or
feedstock in a process.  Recycling  by use or reuse
involves returning a waste material to either the
originating  process  or  another  process as  a
substitute for an input material.  Reclamation is
the recovery of a valuable material, or removal of
impurities, from a waste.
     POLLUTION PREVENTION TERMS

 Pollution Prevention - Reducing or eliminating
 discharges and/or emissions to the environment
 through  the  use  of  source  reduction  and
 environmentally-sound recycling.

 Source Reduction -  Reducing or elimi-nating
 waste at its point of generation.

 Recycling -  Reprocessing waste in a way that
 makes it useful again.  Recycling focuses on the
 use, reuse,  or reclamation -of waste.

 Use or Reuse - Returning a waste material to
 the original process  that generated the waste or
 employing it in another process as a substitute
 for an input material.

 Reclamation -  Recovering valuable mat-erials
 or removing impurities from a waste.
                                               - 2 -

-------
    Because it  is significantly  more efficient  and
 less expensive to prevent the generation of waste
 in the  first  place,  you should consider  source
 reduction  to  be  the  most  preferable  waste
 management option. Source reduction is followed,
 in order of  decreasing  preference, by recycling,
 treatment    (for   example,   incineration   or
 stabilization), and land disposal.
Many Pollution Prevention Options Are Available

    A pollution prevention program might include
 any  number  of  specific  pollution  prevention
 techniques, each with a potentially unlimited range
 of pollution prevention options.   The options
 under each technique that may be appropriate to
 your operation are limited only by your ingenuity.
 Table II provides suggested pollution prevention
 options that  have actually been used in industry.
 The  options are  organized by  technique.   You
 should  use these  suggested options only  as  a
 starting point for your own creativity.  Pollution
 prevention techniques are described below:

 •  Training  and   supervision   --   involves
    providing employees with the  information
    and the incentive necessary to effectively
    minimize waste generation.

         This technique may include ensuring
         that  employees  know  and  practice
         proper and efficient use of equipment
         and supplies, and that they are aware
         of,  understand,  and  support  your
         company's waste minimization goals.

 •  Production  planning and  sequencing   —
    requires  planning  and  sequencing your
    production  so that only  necessary  opera-
    tions are performed  and that no operation
    is  needlessly  "undone"  by  a  following
    operation.

         For example, scheduling printing runs
         from lighter colors to darker ones in
         order  to  reduce the  amount  of
         equipment cleaning required between
         color changes.

 •  Process or equipment modification — involves
    changing the process, or the  parameters or
    equipment used in that process,  to  reduce
    the  amount of waste generated.
        For instance, you can reduce ink loses
        through   vaporization   by  using
        diaphragm   pumps   instead   of
         ;echanical  vane  pumps to reduce
        temperatures,   or   using   high
        pressure/low volume water sprays to
        clean ink vats instead of detergents.
   Raw   material   substitution
involves
   replacing existing raw materials with raw
   materials that will result in the generation
   of less hazardous waste.

        Examples include using water-based
        inks instead of solvent-based ones for
        flexographic and rotogravure printing,
        using  ultraviolet  (UV)-curable  inks
        that do not require solvents, and using
        iron-EDTA   bleaches  instead  of
        ferrocyanide bleaches to avoid cyanide
        generation.

•  Loss prevention and housekeeping — involves
   performing preventative maintenance and
   managing equipment and materials in such
   a way as to minimize the opportunities for
   leaks, spills, and other releases of potential-
   ly hazardous wastes.

        For example, storing light  and heat
        sensitive materials in a place  where
        they   will   not   spoil,   managing
        inventories of time sensitive materials
        so as to avoid expiration of shelf-lives,
        and installing curtains around printing
        areas to contain fugitive air emissions.

•  Waste segregation and separation  -- involves
   avoiding  the  mixing  of different  types of
   hazardous wastes, and avoiding the mixing
   of  hazardous wastes with non-hazardous
   wastes.   This technique will  facilitate  the
                                                   -  3 -

-------
   recovery of hazardous wastes by minimiz-
   ing the number of different hazardous con-
   stituents  in  any given waste  stream and
   avoiding   the  contamination   of  non-
   hazardous wastes.
DRAFT
       This technique includes segregating
       waste inks by color and waste solvents
       by type.

   Recycling -- involves the use or reuse of a
   hazardous waste as an effective  substitute
   for a  commercial  product  or  as  an
   ingredient or feedstock. This use or reuse
   can be on-site, or it can be by another user
   or through a waste exchange.

       Examples   of  recycling   include
       recovering etching wastes, using waste
       inks to make black or a house  color,
       and silver or solvent recovery.
         The Elements of a Successful
        Pollution Prevention Program

   Experience   demonstrates   that   successful
pollution  prevention  programs  have  certain
common elements. These elements are described
below:

•  Suppon from top management -- Support for
   a pollution prevention program should be
   clearly affirmed by your top management in
   a written statement. This statement should
   be circulated among all employees.

•  Explicit program  goals and  objectives  —
   Explicitly identify the goals and objectives
   for the pollution  prevention program in a
   written  statement.    The  goals  should
   include reducing the volume or toxicity of
   the waste as much  as  is technically and
   economically  feasible.    The objectives
   should include a commitment to evaluate
   technologies,  procedures,  and personnel
   training.

•  Accurate waste accounting — Carefully track
   changes over time in the types, amounts,
   and hazardous constituents of your wastes.

•  Accurate cost accounting - Ensure that your
   firm   uses   "fully-loaded"   costs   when
   accounting  for  waste  management  and
   disposal (i.e., costs should  account for all
   liability, regulatory compliance, permitting,
   hauling, treatment, and oversight costs).

•  Involvement of all employees -- Involve all
   appropriate   employees    in   pollution
   prevention planning and implementation.
   You can use rewards and incentives to en-
   courage employee involvement.

•  Exchange  of technology  and information —
   Encourage  exchange of  technology and
   information both within your  firm and
   between your firm and others. Firms often
   contain   a  wealth   of  resources  and
   information that  results from years  of
   operating  experience. Such resources and
   information can play a major role in  the
   efficient   development   of  a  pollution
   prevention program.  Other organizations
   you should consult include  EPA Region's
   and  Headquarter's  pollution  prevention
   information clearinghouses,  state agencies,
   trade associations, universities and colleges,
   nonprofit  business assistance organizations,
   and professional consultants.

•  Periodic pollution prevention assessments -
   Periodically review individual processes (or
   facilities)  to  identify  new  or  changing
   opportunities   to  undertake   pollution
   prevention.

   Basically,  you  should   develop   your  own
program  for  pollution prevention, and wherever
possible, formally define the program in a written
document.     You  should  also  develop   an
implementation plan for each of your facilities or
processes  and  periodically review,  revise,  and
                                               - 4 -

-------
update the program to reflect changing conditions.
You will need a  method of tracking changes  in
waste generation rates and accounting for sources
of waste.    Establishing  an  effective  pollution
prevention  program  is  not difficult, but it does
require commitment from  you  and all of your
firm's employees, including corporate management.
    Where To Go For Information and Help

    While  it is  important  that  you  be actively
involved in establishing and promoting your firm's
pollution prevention  program, you may wish  to
seek the guidance or help of other experts.  Some
organizations  that you  may wish  to  contact
include:
   Trade   Associations
Often    trade
   associations can provide you with pollution
   prevention assistance directly, or they can
   refer you to someone who can.

•  State Waste Management Agencies - These
   agencies  often  have staff  people who are
   knowledgeable  about pollution prevention
   and are willing to provide assistance.

•  Regional Environmental Protection  Agency
   Offices  - There  are ten Regional  Offices
   of the Environmental  Protection Agency.
   The easiest way to find out which Regional
   Office is responsible for your area is to call
   the toll free RCRA/Superfund Hotline (see
   below) and ask for the telephone  number
   or address  of the Regional Office  respon-
   sible for your area.

•  Environmental Protection Agency —  Within
   EPA  Headquarters you may conveniently
   contact  any of the  following information
   sources:

   Hazardous Waste  Minimization  Staff,  at (202)
   382-4807, can provide technical waste minimiza-
   tion information;

   Waste Minimization Branch, at (513) 569-7529,
   can assist you with research and development
   activities    regarding    waste   minimization
   assessments, innovative technology and pollution
   prevention evaluations, and activities of the Waste
   Reduction Institute for Scientists  and Engineers;
                            Pollution Prevention Office, at (202) 382-4335,
                            can  assist  you   in  understanding  pollution
                            prevention and provide you with a great deal of
                            pollution prevention information; and the

                            Pollution Prevention Information Clearinghouse.
                            which includes a collection of reference literature
                            pertaining to  pollution  prevention,  outreach
                            efforts,  the  Electronic  Information Exchange
                            System, and the RCRA/Superfund Hotline:
Electronic   Information   Exchange
System fEIES). at (301) 589-8366, is
an easy-to-use, interactive PC-based
system.  Using a personal computer
and a modem, you  can access EIES
to obtain a wide variety of pollution
prevention information, including case
studies,  a  calendar  of  events,  a
directory of experts, a bibliography of
publications,  and  descriptions  of
federal and state pollution prevention
programs.  You can use an interactive
message center  to  pose pollution
prevention  questions  or  provide
comments   to  other  users.   The
information in Table II that is followed
by an "EIES Number" has come from
references  that are  available to you
through EIES.   You may examine
these   references  for   additional
pollution prevention information  or
ideas.

RCRA/Superfund Hotline, at (800)
424-9346  (or  (202) 382-3000),  can
answer your  pollution  prevention
questions, help you access information
in EIES, and assist  you in searching
for and obtaining documents.
                                       HAVE YOU TRIED
                                  POLLUTION PREVENTION?

                            If you have  tried, or are  planning on trying
                          any pollution prevention activity at your facility
                          and  would  like  to  share  your   ideas  or
                          experience,  use  your  personal  computer to
                          access  the  Electronic Information   Exchange
                          System (EIES) at (301) 589-8366, and let others
                          know!  We can all learn from your experience!
                                                  - 5 -

-------
 How To Use the Pollution Prevention Tables

   Two tables are  included  in this  booklet  as a
quick guide to help you begin identifying specific
pollution   prevention  options.     The  ideas
represented in these tables have been used  at
actual facilities, resulting in cost savings.Table I
identifies typical processes and operations in the
metal  manufacturing industry.   This table  also
identifies typical materials used and types of waste
generated for each  process.

   Table II is also broken down by process and
operation.  Table II, however, provides pollution
prevention options for each process and operation.
These pollution prevention options are organized
by technique, as described in  the previous section.
In addition, Table  II provides examples of  cost
and  savings realized  by  other  facilities,  and
additional relevant information.1  You should use
this  information  to help  decide which options
would best  serve  your needs.   When  properly
installed and  maintained,  none  of  the options
described on Table II should adversely affect the
quality of your products  and all should reduce
your  potential  liability  from  improper  waste
management.  The entries  in Table II  that are
followed by an "EIES Number"  have come from
references that are available to you through EIES.
You may request and examine these references for
additional  pollution prevention  information or
ideas.
lThe cost, savings, and waste reduction information provided in Table II is based on actual case studies and
reflects  the successes of actual metal manufacturing  facilities.  Because specific applications are highly
variable, however, you  should use this  information  only as  an indicator of how a  particular  pollution
prevention option may  perform under your circumstances.

-------
                                                 TABLE I

                 TYPICAL PRINTING AND  ALLIED INDUSTRY OPERATIONS
                                  WHICH MAY PRODUCE WASTES
TYPICAL       TYPICAL
PROCESSOR  MATERIALS
OPERATION   USED
                          TYPICAL
                          MATERIAL
                          INGREDIENT
                          GENERAL TYPES
                          OF
                          WASTE GENERATED
PLATE PREPARATION
*Counter-
Etching to
Remove
Oxides
Phosphoric acid
Phosphoric acid
•    Acid/alkaline wastes
•Deep-Etch
Coating of
Plates
Deep-etch bath
Ammonium dichromate,
ammonium hydroxide
     Acid/alkaline wastes, heavy
     metal wastes
•Etching
Baths
Multiracial plate and
plate coating
Ferric chloride (cop-
per), aluminum/zinc
chloride/hydrochloric
acid (chromium), nitric
acid (zinc, magnesium),
gum arabic
     Acid/alkaline wastes, heavy
     metal wastes
Applying
Light-
sensitive
Coating
Resins, binders,
emulsifiers, photo-
sensitizers, gelatin,
photoinitiators
PVA/ammonium
dichloromate, polyvinvyl
cinnamate, fish
glue/albumin, silver
halide, gelatin,
emulsifiers, gum
arabic/ammonium
dichromate
     Photographic processing
     wastes
Developing
Plates
Developer
Lactic acid, zinc
chloride, magnesium
chloride, hydroquinone
     Photographic processing
     wastes
•Applying
Lacquer
Resins, solvents, vinyl
lacquer, lacquer
developers
PVC, PVA, maleic acid,
methyl ethyl ketone,
cyclohexanone,
isophorone
     Solvent wastes
Using Ink
(lithography,
letterpress,
screen
printing,
flexography)
Pigments, dyes, varnish,
drier, extender, modifier,
fountain solutions
Titanium oxide, iron
blues, molybdated
chrome orange,
phthalocyanine pigments,
oils, hydrocarbon
solvents, waxes, cobalt/
zinc/manganese oleates,
plasticizers, barium-
based pigments
     Waste ink and ink sludges
     with solvents, chromium,
     lead, barium
       Older Technologies

-------
                                          TABLE  I (continued)

                 TYPICAL PRINTING AND ALLIED INDUSTRY OPERATIONS
                                  WHICH MAY PRODUCE WASTES
TOPICAL       TYPICAL
PROCESS OR  MATERIALS
OPERATION   USED	
                         TYPICAL
                         MATERIAL
                         INGREDIENT
                          GENERAL TYPES
                          OF
                          WASTE GENERATED
Making
Gravure
Cylinders
Acid plating bath
STENCIL PREPARATION
FOR SCREEN PRINTING
Copper, chromic acid,
chrome
Plating wastes
Lacquer
Stencil Film
Solvents, polyester film,
vinyl film, dyes
Aliphatic acetates,
cellulose-based lacquer,
plasticizers
Solvent wastes
Photographic
Stencil Film
Organic acids, gelatin
(pigmented), polyester
film base
Acids, alkalies, peroxide-
forming compounds,
plasticizers, surfactants
Acid/alkaline wastes
Photo-
emulsion
Resins, binders,
photosensitizers, dyes
PVA, PVAC,
ammonium or potassium
bichromate, diazonium
compounds
Photographic processing
wastes
Blockout
(screen filler)
Pigmented polymers,
solvents, acetates
Methylene chloride,
methanol, methyl
cellulose acetates
Solvent wastes
PHOTOPROCESSING
Developing
Negatives
and Prints
Developer, cleaning
agents, wetting agents,
fixers, bleaches
Hydroquinone,
ammonium thiosulfate,
silver, lead, chromium,
cadmium, phenol,
toluene, chloroform,
ethylbenzene, methylene
chloride
Photographic processing
wastes
PRINTING
Using Ink
(lithography,
letterpress,
screen
printing
Icxography)
Pigments, dyes, varnish,
drier, extender, modifier,
fountain solutions, inks,
solvents, plates, shellacs
Titanium oxide, iron
blues, molybdated
chrome orange,
phthalocyanide pigments,
oils, hydrocarbon
solvents, waxes,
cobalt/zinc/manganese
oleates, plasticizers,
barium-based pigments,
acrylic copolymers
Heavy metal wastes, ink
sludges with chromium or
lead, ink wastes with metals
or organic constituents, and
solvent wastes

-------
                                       TABLE I (continued)

                TYPICAL PRINTING AND ALLIED INDUSTRY OPERATIONS
                               WHICH MAY PRODUCE WASTES
TOPICAL TYPICAL
PROCESS OR MATERIALS
OPERATION USED
TYPICAL
MATERIAL
INGREDIENT
GENERAL TYPES
OF
WASTE GENERATED

CLEAN UP

Washing/        •    Alcohols, solvents, rags,      •    Ethyl alcohol, benzene,      •     Acid/alkaline wastes, ink
Cleaning             alkaline cleaners                toluene, xylene, isopropyl          wastes with metals or organic
Plates, Type,                                       alcohol, methyl ethyl             constituents, and solvent
Die, Press                                         ketone, trichloroethylene,          wastes
Blankets and                       DRAFT    perchloroethylene,
Rollers                           Ur\f\~ \    carbon tetrachloride,
                                                 gasoline, naphtha,
                                                 kerosene

-------
                                                   TABLE II

                   POLLUTION  PREVENTION PRACTICES FOR PROCESSES
                 AND OPERATIONS IN PRINTING AND ALLIED INDUSTRIES
  POLLUTION     POLLUTION
  PREVENTION   PREVENTION
  TECHNIQUES   OPTIONS
                                             EXAMPLES OF
                                             COSTS AND SAVINGS,
                                             AND OTHER INFORMATION*
PLATE PREPARATION
Process              Use counter-current rinsing to reduce cross
Equipment or         contamination of baths, increase the ease of
Equipment           recycling process baths, and reduce the
Modification          quantity of makeup chemicals required.
                    Use commercially available lithographic plates
                    and film that may be processed with water,
                    reducing or eliminating the generation of
                    waste chemicals. [EIES Number 310-001,
                    p. 208]
Raw Material
Substitution
Reduce the need for photographing and
reshooting by installing electronic imaging
and/or laser platemaking equipment.  [EIES
Number 005-045, p. 3]
Recycling
Reclaim old plates by returning them to the
manufacturer or metal reclaimer.
                    Recover etching wastes (zinc, magnesium,
                    copper) using a packaged etching waste
                    treatment system.  [EIES Number 101-038,
                    p. 331]
                     Recycle type metal (82% lead, 11.5%
                     antimony, 6.5% tin) used in linotype,
                     monotype, and foundry typesetting for the
                     manufacture of letterpress plates.  [EIES
                     Number 101-038, p. 331]
PRINTING
Production
Planning and
Sequencing
Use dedicated presses for inks with
hazardous pigments or solvents.
                     Schedule priming runs from light colors to
                     darker ones in order to reduce the amount
                     of equipment cleaning required between color
                     changes.
    The cosi. savings, and wasie reduciion information provided in Table 11 is based on actual case studies and reflects the successes of
    actual metal manufacturing facilities.  Because specific applicalions are highly variable, however, you should use this information only as
    an indicator of how a particular pollution prevention option may perform under your circumstances.
    These options cost less than S30.000 to implement.

-------
                                             TABLE II  (continued)

                    POLLUTION  PREVENTION PRACTICES FOR PROCESSES
                  AND OPERATIONS IN  PRINTING AND ALLIED INDUSTRIES
  POLLUTION      POLLUTION
  PREVENTION    PREVENTION
  TECHNIQUES    OPTIONS
                                              EXAMPLES OF
                                              COSTS AND SAVINGS,
                                              AND OTHER INFORMATION*
Process or
Equipment
Modification
For general printing on a continuous web:

•   change from indirect steam heating to
    direct gas fired heating;

•   improve air circulation and web
    transport in the over,

•   use heat wheels to pre-heat make-up air.
Capital Investment:  $284,650.  Annual Savings: 5102,100.
Payback Period:  2.7 years.  Waste Savings/Reduction:
solvent discharges reduced from 560 tonnes/year to 200
tonnes/year.  [EIES Number 400-090, p. 16]
                     **  Reduce ink losses through vaporization
                     by using diaphragm pumps (instead of
                     mechanical vane pumps), which will reduce
                     ink temperatures from approximately 100 "F
                     to approximately 80"F.
                                              Capital Investment:  56,000.  Annual Savings:  37,400 (in
                                              recovered solvent).  Payback Period:  10 months.  Product/
                                              Waste Throughput Information: 78.2 tons VOCs per year,
                                              20% of lost solvent  is recovered. [EIES Number 043-005,
                                              pp. 28, 33]
                     Install filters on printing presses.
                                              Waste Savings/Reduction:  ink waste reduced by 30%.
                                              [EIES Number 005-043, p. 62]
                     Keep ink fountains at iheir optimal level for
                     good print quality in large web processes by
                     installing automatic ink levellers.  [EIES
                     Number 005-045, p. 4]
Raw Material
Substitution
Use water-based inks instead of solvent based
inks for flexographic and rotogravure printing
processes in order to reduce hazardous waste
production  (both UV-curable and air drying
systems speed drying of water based inks).
[EIES Number 310-001, p. 209]
Annual Savings:  $57,550.  Product/Waste Throughput
Information:  193,600 Ibs. ink/year. [EIES Number 043-005,
pp. 25, 32]
                     Use foamable aqueous inks rather than
                     solvent-type inks during rotogravure printing.
                                              Operating Cost: same as solvent system.  Waste Savings/
                                              Reduction: VOC emissions reduced by 95%.  [EIES
                                              Number 209-001]
                     Avoid heavy-metal based pigments.
Loss
Prevention
and
Housekeeping
**  Install curtains around printing area to
trap VOC solvent vapors and limit escape to
the atmosphere.
Capital Investment:  $2,000 ($1,000 per printing press).
Annual Savings:  511,100.  Payback Period: 3 months.
Product/Waste Throughput Information: 78.2 tons VOCs
per year; 96,800 Ibs. ink per year.  [EIES Number 043-005,
pp. 25, 28, 32]
                     Wipe off excess liquid using squeegees or
                     doctor blades during printing operations.
                                              Waste Savings/Reduction: can reduce chemical carry-over
                                              by 50%.
                     Reuse rinsewater as long as possible by using
                     contaminated rinsewater for initial equipment
                     rinse.

-------
                                            TABLE II (continued)

                   POLLUTION PREVENTION PRACTICES FOR PROCESSES
                 AND OPERATIONS IN PRINTING AND ALLIED INDUSTRIES
  POLLUTION
  PREVENTION
  TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
                    Exercise inventory control:

                    •    Do not order more ink than can be
                         used before its shelf life expires.

                    •    Completely use a container of ink
                         before opening new one.

                    •    Purchase ink in recyclable bulk
                         containers and recycle empty containers.
                    Instead of disposing unused ink portions,
                    reuse them in "house" colors or future
                    production runs.
                    Return all unemulsified inks to their
                    containers. [EIES Number 005-045, p. 4]
                    Reduce waste ink generation by cleaning ink
                    fountains only when changing colors or when
                    the ink might dry out between  runs.
                    Fountains can be left with ink overnight if
                    sprayed with special non-drying aerosol
                    materials. [EIES Number 005-045, p. 4]
Waste
Segregation
and
Separation
Segregate waste ink according to color and
type and use to thin future batches of the
same ink. [EIES Number 043-005, pp. 28-
29]
Recycling
**  Reuse colored and black inks as printing
ink for newspaper production (discarded inks
can be filtered and mixed with black inks to
produce the newspaper ink).
Capital Investment: 53,720. Annual Net Savings:  $10,000.
Product/Waste Throughput Information:  4,000 tons of
newspaper per year. [EIES Number 400-109, p. 1]
                                                                 Capital Investment: 528,000. Annual Savings: $40,000 in
                                                                 new ink costs.  Product/Waste Throughput Information:
                                                                 260,000 Ibs. waste ink recovered. [EIES Number 310-001,
                                                                 p. 213]
                                                                 Annual Savings:  540,000. Product/Waste Throughput
                                                                 Information:  54,000 gallons waste ink recovered.  [EIES
                                                                 Number 310-001, p. 212]
                                                                 Capital Investment: $8,000. Annual Savings: $28,000.
                                                                 Product/Waste Throughput Information:  1,200 gallons
                                                                 wasie ink recovered. [EIES Number 005-044, p. 41]
                     **   Recover waste solvents through
                     distillation.
                                             Capital Investment:  S3.000 for a 5 gallon batch distillalion
                                             unit.  Payback Period:  less than 1 year. [EIES Number
                                             005-044. p. 60: F.IF.S Number 034-006. pp. 6-7]

-------
                                           TABLE II (continued)

                   POLLUTION PREVENTION PRACTICES FOR  PROCESSES
                 AND  OPERATIONS IN PRINTING AND ALLIED INDUSTRIES
  POLLUTION     POLLUTION
  PREVENTION    PREVENTION
  TECHNIQUES    OPTIONS
                                           EXAMPLES OF
                                           COSTS AND SAVINGS,
                                           AND OTHER INFORMATION*
                                                                Capital Investment: $25,000 for a 110 gallon continuous
                                                                distillation unit.  [EIES Number 034-006, pp. 6-7]
                                                               Capital Investment: $240,000.  Operating Cost $57,600/
                                                               year. Payback Period: 8.2 years.  [EIES Number, 043-005,
                                                               pp. 24-31]
                                                               Waste Savings/Reduction:  3.5 tons of liquid waste reduced
                                                               to 1,100 Ibs. [EIES Number 005-044, p. 58]
                    Use carbon adsorption to recover waste
                    solvents.
                                           Annual Savings: solvent consumption reduced 90%.  [EIES
                                           Number 101-038]
PHOTOPROCESSING
Process or
Equipment
Modification
Use ozone oxidation to regenerate ferric ion
instead of using potassium persulfide.
Waste Savings/Reduction: can reduce ferrocyanide
concentration by 90%.  [EIES Number 310-001, p. 165]
                    Use counter-current rinsing to reduce cross
                    contamination of baths, increase the ease of
                    recycling process baths, and reduce the
                    quantity of makeup chemicals required.
                    Use a "washless" processing system.
                                           Capital Investment: 545,000.  Waste Savings/Reduction:
                                           wastewater reduced bv 97%.
                    Extend the allowable buildup of silver by
                    adding ammonium thiosulfate to silver
                    contaminated baths.  [EIES Number 005-045,
                    p. 3]
                    Use an acid stop bath prior to the fixing
                    bath to reduce the effects of an alkaline
                    developer on the fixing bath's pH. Add
                    acetic acid to the fixing bath to keep the pH
                    low and maximize soluble complexes.  [EIES
                    Number 005-045, p. 3]
                    Use flotation lifts on bleach and developer
                    containers to keep them fresh.  [EIES
                    Number 005-045, p. 3)
                    Reduce the volume of fixer waste by
                    installing waterless paper and film developing
                    units.  [EIES Number 005-045, p. 3]

-------
                                           TABLE H (continued)

                   POLLUTION PREVENTION PRACTICES FOR PROCESSES
                 AND OPERATIONS  IN PRINTING AND ALLIED INDUSTRIES
  POLLUTION     POLLUTION
  PREVENTION    PREVENTION
  TECHNIQUES    OPTIONS
                                            EXAMPLES OF
                                            COSTS AND SAVINGS,
                                            AND OTHER INFORMATION*
Raw Material         Use an aqueous developer to avoid
Substitution           developing in TCE and etching in caustic
                    solution when making decals from photo-
                    resist-coated anodized aluminum.

                    Use silver-free films and carbon black paper
                    systems to reduce the need for silver. Some
                    silverless film does not require a development
                    solution for processing.
                                            Annual Savings: $10,000. Product/Waste Savings/
                                            Reduction: 40% reduction in hazardous waste generation.
                                            [EIES Number 806-001, p. 7]
                    Eliminate silver in wastes by using silver-free
                    films such as vesicular, diazo,
                    electrostatic,and photopolymer films. [EIES
                    Number 005-045, p. 3]
                    Certain commercial films eliminate high
                    polluting substances from both sides of the
                    film.  [EIES Number 101-038, p. 330]
                    Use bismuth as the image carrier instead of
                    silver because of its lower toxicity.  [EIES
                    Number 310-001, pp.  156-157]
Loss
Prevention
and
Housekeeping
Reduce water flow either manually or
automatically (using a solenoid valve) when
actual photoprocessing stops. [EIES Number
310-001, p. 159]
                    Store photosensitive film and paper properly
                    to avoid inadvertent exposure or waste.
                    Reuse rinsewater as long as possible by using
                    contaminated rinsewaters for an initial
                    equipment rinse.
                    Wipe off excess liquid using squeegees or
                    doctor blades during processing.
                                            Waste Savings/Reduction:  can reduce chemical carry-over
                                            by 50%.  [EIES Number 310-001, pp.  158-159]
                    Protect process baths that spoil easily by
                    keeping them containerized. [EIES Number
                    005-045, p. 3]
                    Minimize bad runs and waste by using
                    commercially available continuous monitors.
                    (EIES Number  005-045. p. 3]
                                                       14 -

-------
                                            TABLE  II (continued)

                    POLLUTION PREVENTION  PRACTICES FOR PROCESSES
                 AND  OPERATIONS IN PRINTING AND ALLIED INDUSTRIES
  POLLUTION      POLLUTION
  PREVENTION    PREVENTION
  TECHNIQUES    OPTIONS
                                              EXAMPLES OF
                                              COSTS AND SAVINGS,
                                              AND OTHER INFORMATION*
Recycling
                     Use glass marbles to bring the liquid level in
                     the process baths to the brim each time the
                     liquid is used. [EIES Number 005-045, p. 3]
**  Use electrolytic recovery cells to plate
pure silver out of the waste stream.
                     **   Reclaim metal from silver-bearing
                     effluent with a chemical recovery cartridge.
                     Multiple chemical recovery cartridges in
                     series will increase silver recovery.

                     **   Use chemical precipitation, such as
                     sodium borohydride reduction, to recover
                     heavy metals and  to control discharge.
                     [EIES Number 310-001, p. 162]
                     Recover spent bleach, especially ferricyanide,
                     using:

                     •    ozone oxidation,
                     •    electrolysis,
                     •    persulfate salts,
                     •    liquid bromine.
                     [EIES Number 310-001, p. 165]
Capital Investment:  $150 to over $15,000.
                                              Waste Savings/Reduction:  98% silver recovery from spent
                                              fix. [EIES Number 310-001, pp. 163-164]

                                              Capital Investment:  cost of cartridges $30-$50.
                                              Capital Investment:  $7,000 to $10,000. Operating Costs:
                                              $0.15 per ounce of recovered silver for x-ray fixers; $0.50
                                              per ounce for bleach fixers.  Product/Waste Throughput
                                              Information: 400 gallon capacity treatment system.  [EIES
                                              Number 507-001, pp. 145-147]
CLEANUP
                     Recycle color developer using oxidation
                     recovery.
                                             Capital Investment:  $54,200 (1981).  Payback Period: 2
                                             years. [EIES Number 310-001, p. 169]
                     Recycle waste or spoiled photographic film
                     and paper.
                                             Waste Savings/Reductions: drummed scrap films can be
                                             sold. (EIES Number 101-038; p. 330]
Process
Equipment or
Modification
When cleaning caked-on deposits from the
sides of ink vats, save water by using a high
pressure spray unit instead  of detergent.
Waste Savings/Reduction: wash lime per vat reduced 52%;
volume of wasie water generated reduced 54%.  [EIES
Number 808-001, p. 31]
                     **   Reduce fountain tray cleaning costs by
                     installing portable fountain cleaning and
                     reclaiming equipment.
                                             Capital Investment:  $4,000 (1977).  Annual Savings:
                                             $375,000. Product/Waste Throughput Information:  18 ink
                                             fountains cleaned weekly. Waste Savings/Reduction: 80%
                                             of ink is recovered. [EIES Number 310-001, pp. 213-214]
                                                         15 -

-------
                                              TABLE  H (continued)

                    POLLUTION  PREVENTION  PRACTICES FOR PROCESSES
                  AND OPERATIONS  IN PRINTING AND ALLIED INDUSTRIES
Raw Material
Substitution
Use less toxic solvents with press wipes (i.e.,
nonchlorinated solvents such as alcohol,
mineral spirits, water, etc.).
Loss
Prevention
and
Housekeeping
Do not draw too much cleaning solvent from
a drum.  Use only as much solvent as
required when cleaning.
                      Use press wipes for as long as possible
                      before throwing them out.  Use dirty ones
                      for the first pass and clean ones for the final
                      pass. Similarly, use dirty solvents during the
                      first cleaning and fresh solvent for the final
                      cleaning.
Recycling
Use dual distillation units to transform spent
press and roller cleanup solvents into dry,
solvent-free cakes.  For example:
                              55 gallon batch still.
                                               Capital Investment: $15,000 to $16,000.  Annual Savings:
                                               $24,000.  Payback Period:  less than one year.  Waste
                                               Savings/Reduction:  60%.  [EIES Number 034-006, pp. 7-8]
                              20 gallon (continuous) still.
                                               Capital Investment: $9,000.  Annual Savings:  514,400 to
                                               536,000.  Payback Period:  6 months. Waste Savings/
                                               Reduction:  100%. [EIES Number 034-006. pp. 7-8]
                          Distill all waste solvents.
                                               Capital Investment: 53,000 (5 gallon batch still).  [EIES
                                               Number 034-006, p. 6]
                      Send spent solvents back to the formulator
                      for use in future batches.
                                                                     Capital Investment:  $25,000 (110 gallon continuous still).
                                                                     [EIES Number 034-006, p. 6]
                      Clean press-cleaning wash waters by routing
                      them through an ultrafiltration unit (UF) and
                      return them to the process.
                                               Capital Investment: $63,000.  Operating Cost:  $19,300.
                                               Savings:  $125,000 (when UF is compared to hauling at
                                               $0.10/gallon).  Payback Period:  1.08 years. Product/Waste
                                               Throughput Information: 5,000 gallons/day. Waste
                                               Savings/Reduction:  98% volume reduction. [EIES Number
                                               999-001]

-------