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P March 1996
8EPA
Lithographc Printers
This document was prepared for the U.S. Environmental Protection Agency by Science Applications International Corporation, 20 California Street, Suite 400, San Francisco, California 94111, under Contract No. 68-W4-0005, Work Assignment No. R09003, DCN: RZ3-S AI-R09003-0 1 -TR-00968.
DISCLAIMER
Referencing specific product names is for example purposes only and does not constitute an endorsement by the U.S. EPA.
Costs are generally based on 1994-1995 information. Users of this Guide should update costs or disclose that they are 1994-1995 figures.
ACKNOWLEDGEMENTS
The U.S. Environmental Protection Agency and the authors of this document acknowledge the extremely valuable contributions of trade organizations, businesses, state and local agencies, educational and business assistance organizations and individuals who participated in focus groups to review this Guide and who commented on subsequent drafts as peer reviewers.
PoLLUnON PREVENTION LITHOGRAPHIC PRINTERS TRAINING IW"RUc"ORs' GUIDE
TABLE OF CONTENTS
ABOUTTHISGUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAMPLE WORKSHOP AGENDA ................................. Vi
WORKSHOP PRESENTATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Presentation I: Introduction to Pollution Prevention . . . . . . . . . . . . . . . . . . . I - 1 Presentation 11: Pollution Prevention Techniques for Lithographic Printers . . ,. . II - 1 Presentation 111: Implementing Pollution Prevention . . . . . . . . . . . . . . . . . . III . 1
Appendices
Appendix A: Overheads of Workshop Presentations Appendix B: List of Text and Photo Slides Appendix C: Text and Photo Slides of Workshop Presentations Appendix D: Fact Sheet Appendix E: Disks Appendix F: Practical Pollution Prevention Techniques for Lithographic Printers,
U.S. EPA Region IX and California Department of Toxic Substances Control, April 1994.
Appendix G: Additional References Appendix H: Diagram of Major Wastes Generated by Lithographic Printing
i MARCH 1996
mLLUTION PREVENTION LITHOGRAPHIC PRINTERS TRAINING ~~~TRUCTORS' GUIDE
ABOUT THIS GUIDE
This Pollution Prevention (P2) Training Instructors' Guide is a product of the U.S. Environmental Protection Agency's (EPA's) Small Business Pollution Prevention Assistance Program. The Guide provides trade associations, local government agencies and educational institutions with a valuable tool to train lithographic printers in pollution prevention. This Guide is designed to support a workshop for printing facility owners, managers and employees. These materials could also be used to support training of regulatory agency managers and staff who provide P2 assistance to business through outreach and inspection programs. Many of the P2 opportunities discussed in the Guide are relevant to other types of printers. The workshop materials should be introduced following a presentation on regulatory requirements that apply to the industry or be given to attendees who are already familiar with the relevant regulations.
Organizations offering pollution prevention training should be able to base some or most of a half-day workshop on the Guide. Speakers are encouraged to tailor the workshop materials to their own needs. For instance, they may choose to modify presentations in the workshop, include additional information, or not use a particular presentation.
An organization's specific workshop objectives will determine how much of the Guide can actually be used. These materials are more suitable for workshops that focus on printing F 2 opportunities than training sessions that focus on distributing information on specific products, technologies and vendors. Although some of this specific information is contained in the Guide and in Appendix F, users are encouraged to supplement these materials with more specific and local information.
The Guide includes 35-millimeter photo slides along with the workshop materials in Appendices A-C. A four-page fact sheet that complements the workshop is included in Appendix D. Computer disk versions of all documents are provided in Appendix E to allow for easy modifications. The Guide is in WordPerfect 5.1 and the fact sheet is in PageMaker 5.0. Users are encouraged to incorporate their own logos and additional graphics into the fact sheet and workshop materials.
Instructors must have some knowledge of the lithographic printing industry but need not be "experts. " Supplemental information labeled as "instructors' notes" provides speakers with suggestions and more detailed information (e.g., costs, products and examples) that can be shared with audiences as appropriate. The workshop materials are written as a script to make giving the presentations as easy as possible. Although you can read the script, instructors who give the training in their own way will be more effective.
.. 11 MARCH 1996
I-
-
mLLUnON PREVENTION LITW~GRAPHIC PRINTERS TRAINING INSTRUCTORS’ GUIDE
This Instructors’ Guide includes “ready to go“ overheads for transparencies or slides for three presentations.
Presentation I: Introduction to Pollution Prevention
Presentation 11: Pollution Prevention Techniques for Lithographic Printers
Presentation 111: Implementing Pollution Prevention
The sample agenda suggests time frames for each presentation.
The body of this Instructors’ Guide provides overheads with notes for these components of the training.
The appendices include overheads (without instructors’ notes). These overheads are also provided on disk in Freelance Graphics for Windows, Version 2.0 to allow for imaging of revised slides. The appendices also include a list of text and photo slides for your convenience, color text and photo slides, a fact sheet, and a document entitled PrucficaZ PoZZm’on Prevention Techniques for Lithographic Printers (1994) prepared for U.S. EPA and the State of California with the cooperation and assistance of the Printing Industries of Northern California. Much of the specific information in this Guide is based on this document.
Interaction with and among workshop participants should be encouraged and will help make your workshop more successful. Input received directly from printing facility owners, managers and employees is invaluable.
Similar Instructors’ Guides are available for automotive maintenance and repair and residential construction. Contact EPA’s library in San Francisco at (415) 744-1510 in order to obtain a copy of these Guides.
For more information on P2 in the lithographic printing industry, refer to the publications listed in Appendix G. Also, contact printing industry trade associations, such as the Printing Industries of America, vendors and your state and local p2 programs. These organizations can be very helpful.
... 111 MARCH 1996
POLLUTION PREVENTION LITHOGRAPHIC PRrmTERS T-G I”RUCT0RS’ GUIDE
x:xx - x:xx x:xx - x:xx x:xx - x:xx
SAMPLE WORKSHOP AGENDA
Introduction to Pollution Prevention (15 minutes)
Pollution Prevention Techniques for Lithographic Printers (90 minutes)
Implementing Pollution Prevention (45 minutes)
iv MARCH 1996
I -
PoLLUnON PREVENTION TRA!”G I”UCT0RS’ GUIDE
WORKSHOP PRESENTATIONS
1 MARCH 1996
PRESENTATION I: INTRODUCTION POLLUTION PJtEVJDITION
TRAINING ~STRUCTORS~ GUIDE
PRESENTATION I
Slide 1-1
INTRODUCTION TO POLLUTION PREVENTION
I - 1 MARCH 1996
PoLLUTION PREVENTION PRESENTATION I: INTRODUC~ON TW”G I”UCTORS’ GUIDE
Slide 1-2
WORKSHOP OVERVIEW
1. INTRODUCTION TO POLLUTION PREVENTION
11. POLLUTION PREVENTION “ I Q U E s
111. IMPLEMENTING POLLUTION PREVENTION
Pollution prevention (P2) is the most effective way to solve pollution-related problems that impact your business’ bottom line and the environment. Problems include permitting and employee health concerns associated with volatile organic compound (VOC) emissions and, in many areas, costs associated with meeting wastewater discharge requirements. Pollution prevention offers a win-win solution to most of these problems because P2 protects the environment and often saves money.
This workshop will:
1) Define pollution prevention and give an overview of its benefits (Presentation I);
2) Provide information on a range of pollution prevention methods and techniques that directly address pollution-related problems. For each technique, we will look at the problem it confronts and highlight pros and cons, including performance, cost/savings and other considerations (Presentation II); and
3) Give you the tools to evaluate and select pollution prevention techniques (Presentation III).
[Instructors’ Note: Speakers may choose to cover more than one presentation. For example, you may w ~ n t to combine Presentations I and II into a single introductory presentation. ]
1 - 2 MARCH 1996
m L L U n O N -ON PRESENTATION k INTRODUCTION TRAINING INsLaucTo~s' GUIDE
Slide 1-3
WHAT IS POLLUTION PREVENTION ?
SOURCE REDUCTION
RESOURCE CONSERVATION
REUSE AND RECYCLING
Pollution prevention is a more efficient use of materials and resources in order to generate less waste and emissions. It is preferred over traditional pollution control approaches, like treatment and disposal, which often just shift pollution around (e.g., from land to water) without eliminating it.
Every printer employs some of the pollution prevention techniques that will be discussed in this workshop. Printers may refer to these techniques simply as "good business practices" or "standard operating procedures." Some may know them as waste reduction or waste minimization. Many of these techniques also apply to other types of printers. Although p2 is required by certain environmental regulations, it is usually completely voluntary.
Source reduction, the top pollution prevention priority, is any practice which reduces the amount of pollution generated and associated hazards to the public and the environment.
Source reduction includes:
Substitutes of raw materials; Improvements in housekeeping, maintenance, training, and inventory control; Equipment or technology modifications; Process or procedural modifications; and Reformulation or redesign of products.
P2 applies to general operations and each step of the printing process: prepress, press and postpress.
Examples of source reduction include:
prep-
* Use computers to set up and edit jobs to produce proofs for client approval. This technique reduces photoprocessing wastes because "soft proofing" on a computer is possible.
1 - 3 MARCH 1996
PoLLUTION PREWNTION PRESENTATION I: INTRODUCTION TR,U"G I N ~ U C T O R S ' GUIDE
Employ aqueous plate processing chemicals to reduce or eliminate the use of hazardous developers and fixers. You may be able to discharge wastewater from the aqueous process to the sanitary sewer.
Press
Maximize use of vegetable-based inks that significantly reduce VOC emissions. Soy-based inks with 1% VOC content are available. These inks reduce air emissions and improve employee health.
Pollution prevention also includes resource conservation measures and other practices that reduce or eliminate the creation of pollutants through:
Increased efficiency in the use of raw materials, energy, water, and other resources, and
Protection of natural resources.
Examples of resource conservation include:
Conserve energy by using energy- efficient lights and equipment and turning them off when not in use.
Conserve water by installing water- saving devices, reusing water and using only what you need.
Examples of reuse and recycliag include:
Segregate wastes to increase recyclability.
Contract with a hauler to send used film and film scraps, developer, and recovered silver offsite for silver recycling.
Reuse dirty solvents for initial wipe down of equipment, followed by a final cleanup using clean solvent. This reduces the quantity of solvents you purchase.
Send your shop towels to any industrial laundry. Clean towels can be obtained from the laundry service. Purchasing new shop towels is reduced. However, laundry services may not accept shop towels that are heavily contaminated. These towels may be considered hazardous wastes.
We will discuss these and other examples in detail in a few minutes.
Although reuse and recycling are lower priorities than source reduction and conservation, these activities, conducted in an environmentally sound manner, share many of the advantages of P2.
1 - 4 MARCH 1996
mLLUnON PREVENTION TRAINING INSTRUCTORS’ GUIDE PRESENTATION I: INTRODUCTION
Slide 1-4
WHY POLLUTION PREVENTION?
SOLVE POLLUTION-RELATED PROBLEMS
SAVEMONEY
PROTECT ENVIRONMENT
~
Many of you view pollution prevention as a good business practice that helps make you successful. Overall, P2 is a powerful way to solve pollution-related problems. As the examples we will discuss show, P2 can address problems, save money and protect the environment by:
p2 can also help you enhance or maintain a -positive image within Your communityA
[Instructors’ Note: This is a good time to ask your audience about their understanding of P2. But leave the speciJc discussion of P2 techniques to Presentation II.]
Reducing raw materials use and costs,
Cutting waste recycling, treatment and disposal costs,
Improving operations and efficiency,
Helping you comply with environmental regulations more easily,
Minimizing air emissions and waste water discharges,
Protecting employee health and safety, and
Reducing liability and associated costs.
1 - 5 MARCH 1996
- 1
POLLUTION PREVENTION PIWENTATION I: INTRODUCTION TRAINING INSTRUCTORS' GUIDE
Slide 1-5
YOUR COMMITMENT TO P2
MANAGEMENT COMMITMENT
INFORMATIONAL PROGRAMS
INCENTIVE PROGRAMS
Pollution prevention requires your commitment.
First and most importantly, printing facility owners and managers must be committed to pollution prevention. That commitment should be passed on to employees.
Supervisors should provide information and training on pollution prevention to all employees. This workshop stresses the importance of training and awareness building as essential steps in a successful pollution prevention program.
Incentive programs for employees that encourage pollution prevention should be developed and implemented. For example, consider giving a free dinner monthly or quarterly to employees who do a good job in improving facility P2 and efficiency. Don't forget to make the dinner for two--no one likes to eat alone.
1 - 6 MARCH 1996
POLLUTION PREVENTION PRESENTATION II: POLLUTION PREVENTION TECHNIQUES ~ ~ R X T O R S ’ GUIDE
Slide II-1
PRESENTATION I1
POLLUTION PREVENTION TECHNIQUES
FOR LITHOGRAPHIC PRINTERS
I1 - 1 MARCH 1996
POLLUTION m V E " I 0 N IrJsrrrvcToRs' GUIDE PRESENTATION Ik P~LLUTION PREVENTION TECHNIQUES
Lithography, the largest sector of the printing industry, accounts for 47% of the U.S. market share. Many of the estimated 35,000 lithographers in the U.S. are small businesses with fewer than 10 employees. Less than 15% of lithographic printers employ more than 20 people.
Slide 11-2
OVERVIEW
a PRINTING PROCESS STEPS, MATERIALS USED, WASTES AND EMISSIONS
a P2 TECHNIQUES FOR EACH STEP OF THE PRINTING PROCESS
a ECONOMIC AND ENVIRONMENTAL BENEFITS OF POLLUTION PREVENTION
The U.S. EPA places printing in the top 10 U.S. industries for amounts of toxic waste released to the air, water, and land and disposed of in hazardous waste management facilities. In 1990, printing and allied industries generated 56 million pounds of toxics based on Toxic Release Inventory (TRI) reporting. This figure is likely higher because many small and medium size businesses are not required to report under the TRI program.
pollution-related problems they can solve, and the economic and environmental benefits associated with each.
[Instructors' Note: Although we will address the major processesses, wastes generated and pollution prevention techniques that apply to this industry, we could not possibly cover everything in this brief training session. Ask the audience to let you know if there are important P2 methods that are missing.]
In this presentation, we will briefly review printing processes, materials used, wastes generated, and other forms of pollution associated with this industry. Then we will discuss €2 techniques, including which
I1 - 2 MARCH 1996
POLLUTION PREVENTION PRESENTATION Ik POLLUTION PREVENTION TECHNIQUES TRAINING bU!jTRUCTORS' GUIDE
Slide II-3
PRINTING STEPS
0 PREPRESS - IMAGE PROCESSING AND PLATEMAKING
0 PRESS
0 POSTPRESS - BINDING AND FINISHING
In terms of pollution prevention, lithographic printing can be organized into three steps:
prepress including image processing and platemaking,
press, and
0 postpress.
The processes to prepare an image and transfer it to a plate are similar because a photographic process is used in both activities.
The press step includes everything that occurs on and around a printing press. Press cleanup is an important activity in printing.
Postpress involves binding and finishing.
Breaking down printing like this should be familiar - many of you develop bids for jobs by looking at the cost of each step. Also,
most printing facility employees look at printing this way.
Remember that, regardless of the step, pollution prevention techniques are based primarily on reducing the amount and toxicity of materials used and the wastes generated.
[Instructors' Note: In order to understand the pollution-related problems or concems that your audience may have, you may want to ask participants about what processes, equipment and materials they use and their issues. This will help you decide which processes, problems and P2 techniques to focus on.]
Wastes are generated from materials and resources used in each step and from cleaning press equipment. The diagram on page 11-6 will help you understand the relationship between the materials you use and the wastes that are generated.
I I - 3 MARCH 1996
PoLLUTION PREVENTION T W G INsTaUCToRs’ GUIDE PRESENTATION II: POLLUTION PREVENTION TECHNIQUES
[Instructors’ Note: You should hand out this diagram to your audience. Use the version in Appendix H. To encourage your audience
various processes, consider covering up the bottom section of the diagram and asking your audience to name the wastes generated.]
- to think about the wastes generated by the
Because image processing and platemaking are similar processes, they use similar materials and generate similar wastes.
The major wastes generated by the three steps include:
0 Film
0 Wastewater -- spent fixer and developer
0 Silver
0 Toner
0 Toner cartridges
0 Water and energy
Platemaking
0 Wastewater -- aqueous developer (usually nonhazardous)
0 Used plates -- aluminum, plastic, paper, others
Press
0
0
0
Waste ink (waste and reusable)
Waste paper (including film scraps)
VOC emissions from inks, solvents, fountain solutions
0 Empty ink containers
0 Waste press lubricating oils
0 Energy
Cleaning Equipment
0 Waste solvent
0 Cleanup towels
0 Waste ink
0 Empty solvent containers
vocs 0 Wastewater
0
Postpress
Waste paper trimmings
vocs Waste glue
Energy
0 Water and energy
I1 - 4 MARCH 1996
POLLUTION PREVENTION TRAINING INsTRucIy)Rs' GUIDE PRESENTATION n: PoLLUTlON PREVENTION TECHNIQUES
This presentation will now focus on the source reduction, resource conservation, reuse and recycling techniques that will help you reduce waste and address pollution- related problems associated with prepress, press and postpress processes.
The costs of these techniques, as well as their payback to your business and the environment, will be highlighted.
Before we get into the specific techniques and methods, I want to mention the importance of evaluating the techniques to determine if a technique will work for your facility. Although many of these techniques may be feasible, each facility has different constraints. Presentation III will provide some tools to help you determine whether a technique will work for your facility.
I1 - 5 MARCH 1996
I
PoLLUTION -VENTION TRAINING IN~UCTORS' GUIDE PRESENTATION 11: PoLLUTlON PREVENTION TECHNIQUES
Major Wastes Generated by Lithographic Printing
MATERIALS
Film Photo processing
Energy fixers & developers
WASTES
Film Wastewater
Silver Toner Toner cartridges Water Energy
(spent fixerldeveloper)
Plates: aluminum, plastic & other types Water Energy
Wastewater Aqueous developer Used plates Water Energy
WASTES FROM CLEANING PRESS EQUIPMENT Waste solvent Cleanup towels Waste ink
Empty solvent containers vocs Wastewater
Inks: vegetable (e.g., soy & linseed),
Fountain solutions: isoprqy/ alcohol
Press lubricating oils, cleaners Paper Water
rubber, oil based, ultra violet
(IM), non-IPA
Energy
Waste ink Waste paper vocs Empty ink containers Lubricating oils
Paper Glue Binding (e.g., comb) Energy
Waste paper trimmings
vocs Waste glue Energy
I1 - 6 MARCH 1996
I :
mLtUTION FkEVENTION PRESENTATION II: POLLUTION PREVENTION TEcriNIQUES TRAINING INSI’RUCTORS’ GUIDE
Slides 11-4, 6, 9
INVENTORY CONTROL
e ESTABLISH INVENTORY CONTROL SYSTEM
0
e
0
e CONTROL ACCESS
0 HANDLE MATERIALS CAREFULLY
USE MATERIALS FOR INTENDED PURPOSE
LABEL, DATE, AND INSPECT MATERIALS WHEN PURCHASED
USE A “FIRST IN FIRST OUT” POLICY
Even before you create an image or run a job, you can make decisions that affect waste generation. Prior to looking at prepress, our first printing step, it’s important to review proper inventory control, which affects waste generation throughout the facility.
Properly controlling inventory is a relatively easy, cost-effective way to ensure that materials are used efficiently, do not go to waste, or become a problem. Inventory control techniques include:
0 Establishing an inventory control system that tracks supplies and materials and minimizes the purchase of unneeded materials (e.g., just in time systems). Why purchase new ink if you have the
necessary color onsite? There are simple methods and software packages available to help you accomplish this task. Go to Sli& II-5 which shows a printer’s ink inventory.
[Instmtors ’ Note: Ink and solvent inventory can be controlled to avoid wastes generated by expiration of materials beyond their sher life. Any expired inks and solvents murt be handled ashazardous waste. The minimum cost for disposal of these expired materid is at least $300 per 55-gallon dnun.]
Go to Slide 11-6.
I I - 7 MARCH 1996
mLX,UTION PREVENTION PRESENTATION II: POLLUTION PREVENTION TECHNIQUES TRAINING INSTR~CT~RS~ GUIDE
Using materials only for their intended purpose. For example, don't use a solvent to clean a spill that a shop towel or a wipe could handle.
0 Labeling, dating and inspecting stock as it is received. Use the earliest labeled stock first to prevent material degradation and loss (i.e.,follow a 'Erst in first out" policy).
0 Control employee access to materials. Designate one or a limited number of employees to maintain and have access to supplies to ensure that employees do not use more materials for a job, or for a cleaning, than are necessary. The pressroom supervisor may be a good candidate for this job.
0 Improving procedures for storing and handling materials carefully to prevent spills. Storing materials to prevent spills (e.g., not overstacking) and keeping supplies in contained areas to control spills that may occur. Your inventory control coordinator should also have overall responsibility for maintaining storage areas. However, this coordinator could delegate this task to another employee. Go to Slides 11-7 and II- 8 which show proper containment of acids and flammable materials.
Go to Slide II-9.
Facility owners and managers should encourage employees to properly control inventory by establishing written procedures and communicating these procedures to employees through training and by posting signs and notices around the facility. Provide incentives to employees to practice pollution prevention, such as considering their efforts in salary reviews and having an awards program (e.g., employee of the month program that encourages job performance including setting a good example for P2 and efficiency).
I1 - 8 MARCH 1996
I -
POLLUTION PREVENTION TRAINING I”UCT0RS’ GUIDE PRESENTATION n: POLLUTION PREVENTION TECHNIQUES
Remember that prepress includes image processing and platemaking.
Slides II-lo, 12 Prepress-Image Processing
BEST MANAGEMENT PRACTICES AND MATERIALS SELECTION
e
e PHOTOGRAPHIC CHEMICAL MANAGEMENT
e MATERIALS SELECTION/SUBSTITUTION
INVENTORY CONTROL AND PROPER STORAGE
Image processing is preparing art or copy, typesetting, and photoprocessing. The primary wastes during image processing are processing chemicals, silver, wastewater, toner and toner cartridges. Pollution-related concerns in this step are meeting wastewater discharge limits, primarily for silver, reducing product loss and energy and water costs, and recycling toner and toner cartridges.
Recent developments in electronic technology, such as desktop publishing and digital prepress, help to reduce or eliminate many of these photoprocessing wastes. These technologies will be covered at the conclusion of our discussion of image processing.
Without incurring the expense of modifying equipment, you should be able to reduce waste and costs and increase
efficiency by employing best management practices (BMPs) and selecting less toxic materials.
What are BMPs?
e Practicing inventory control and proper storage are particularly important in image processing because of the many chemicals used. In addition to the general inventory control and storage techniques we just reviewed, other methods are specific to this step:
- Store chemicals sensitive to temperature and light according to manufacturers’ directions.
- Keep storage areas free of dust and other contaminants that could destroy materials.
I1 - 9 MARCH 1996
POLLXITION PREVENTION PRESENTATION Ik POLLUTION PREVENTION TECiiMQUES TRAINING M~~RUCTORS' GUIDE
- Whenever feasible, purchase materials used heavily in bulk. This technique applies more to larger printers. Returnable or refillable totes are available from many vendors. Go to Slide II-11 which shows large, returnable and refillable containers of photoprocessing chemicals.
Go to Slide 11-12.
Improving photographic chemical management involves several techniques:
0 Reducing unnecessary changeouts is an effective reduction technique. Photoprocessing bath solutions (developer and fixer) should be monitored closely to decide when they are no longer effective and need changing. They should only be changed when they are no longer effective.
0 Reducing or eliminating air emissions and product loss by fitting photoprocessors with covers and lids. Covers and lids must allow hookups to the photo- processor as necessary. Developers have a volatile content of between 65 and 85%. Fixers are between 40 and 65% volatile. Containment system costs range from $20.00 to $50.00 per photo processing unit.
0 Adding bath life extenders. Adding ammonium thiosulfate should double the allowable concentration of silver buildup in the bath. Using an acid stop bath prior to the fix bath and adding acetic acid to the fixing bath will help keep the pH low.
Remind employees of these and other BMPs with brief informational or training sessions and with signs and notices.
Material substitutes that cause less waste to be generated include:
0 Using photographic intensifiers that do not contain hazardous compounds, such as mercury or cyanide salts.
0 Using silverless films, such as electrostatic films, that have speeds and resolution comparable to silver films. Electrostatic films become light sensitive with an electrostatic charge.
Ask photographic vendors for nonhazardous or less hazardous substitutes and for recycled fixers and developers. Nonhazardous developers and finishers that are reported to be nontoxic and have a flash point over 200" F are available. Recycled fixers and developers are compatible with automatic processors.
Now we will discuss ways to modify your photoprocessing equipment to further reduce waste.
I1 - 10 MARCH 1996
m L L U n O N PREVENTION TruINnvc ~ U C T O R S ' GUIDE PRESENTATION II: POLLUTION PREVENTION TECHNIQUES
Slide 11-13 Prepress-Image Processing
EQUIPMENT MODIFICATIONS
0 AUTOMATIC WASH BATHS
0 PHOTOPROCESSOR STANDBY OPTIONS
0 WATER CONTROL UNITS
0 WATER RECIRCULATION UNITS
0 SQUEEGEES
0 SILVER RECOVERY UNITS
Modifying image processing equipment typically involves low to moderate capital expenditures. Most are "modifications" or improvements to your existing equipment in order to increase processing efficiency. Purchasing new image processing equipment is usually not necessary. 0
0 An automatic wash bath installed on a photoprocessing unit operates only when film is being processed thereby reducing water usage and wastewater generation.
0 Photoprocessor standby options significantly cut energy use. Standby options shut down all processor functions when not in use except those that maintain solution bath at required temperatures.
New equipment is typically fitted with standby options. It may be possible to retrofit older units. Compare the cost of retrofit to the savings from reduced energy costs.
Water control units can substantially reduce wastewater due to a decrease in fresh water use. A control unit is basically an electronic valve that only turns on when film is being processed. Wall-mounted control assemblies are available to control the flow and temperature of water to the wash bath. The Kodok W'er Control Assembly, Model 20 is one such unit.
I I - 11 MARCH 19%
POLLUTION PREVENTION TRAINING INSTRUCTORS' GUIDE =ATION n: POLLUTION PREVENTION TECHNIQUES
[Instructors' Note: Wall-mounted control units can be installed with any photoprocessor equipment. A typical processor uses I . 3-2. 6gallons of wash water per minute. If the wash water is allowed to run for an 8-hour period, between 624 and 1,248 gallons of water would be required. Water control units can reduce water consumption by as much as 90%.
Control units sell for approximately $I ,2W. Cost savings should be realized from decreased water use and lower wastewater discharge fees. Assuming a savings of between 560 and I , 120 gallons of water per day, at a cost of $1.02 per unit (I unit is 748 gallons), a savings of between $23 and $45 per month ($276-540 per year) would be realized. Wastewer discharge savings may amount to between $95 and $190per month ($1,140.2,280 per year), at a discharge fee of $4.25 per unit. The payback period for a water control unit can be less than I year.]
e Install an "off-the-shelf" water recirculation unit to reuse photo processing wash bath water and to reduce energy costs. This measure reduces fresh water use because wash bath water is reclaimed and reused. It also cuts energy costs because the recirculated water is already warm. Recirculation units cost at least $500. Additional costs include installation (mostly replumbing) and operating maintenance expenses.
e Squeegees can be used on non- automated systems to wipe excess
liquid from the 4ilm and paper to limit carryover to the next bath and reduce fluid loss. Squeegee rollers or blades or air squeegees are available; rollers are most common. Very efficient squeegees can remove all carryover from the film surface (some is absorbed by the emulsion, estimated at 4.5-5.0 milliliters per square foot). Without wiping action, commonly 10 milliliters per square foot is carried over. Silver carried from fixer solution to the wash bath can lead to wastewater discharge violations. According to Kodak Company literature, rack-and-tank, basket, or drum processor equipment cannot be fitted with
realized from reduced material needs. Efficient squeegees can save (from carry out) about 3.3 milliliters per square foot of solution. This reduces the bath replenishment rate by between 50% and 90% and saves on the cost of purchasing developer and fixer ($40-50/five gallons).
squeegees. cost savings are
e Silver recoverycan occur onsite or offsite. Many small printers find it's more cost effective to have their fixer hauled to an offsite recycler. If you choose to recover silver onsite, you can use several different types of equipment. Recovering silver from your fixer bath typically extends the life of the bath by 60 to 90% if you have a recirculating silver fecovery
I1 - 12 MARCH 1996
POLLUTION PREVENTION PRESENTATION 11: POLLUTION PREVENTION TECHNIQUES INSTRUCTOJCS' GUIDE
system. This technique can also help you meet silver concentration wastewater discharge limits. You may also be able to recycle scrap film and paper for silver content. Go to Slide 11-14 which shows an electrolytic silver recovery unit.
[Instructors 'Note: The most common silver recovery units are electrolytic or metallic replacement. The electrolyticprocess, which is principally used to extend bath lve and metallic replacement, is generally employed to meet discharge limitations. An electrolyticprocess passes the jixer (or hypo) between two electrodes. Almost pure silver collects on the negatively charged electrode and is removed periodically by faciliy personnel.
Metallic replacement passes the hypo through a specially designed cartridge that contains steel wool. The iron in the steel wool reacts with thecfixer. The iron releases into the &er and the silver collects on the steel wool.
With the electrolytic method, silver is removed from the electrode by scraping it out. A metallic replacement cartridge must be sent ofsite for processing. Electrolytic units require a largerinitial investment than metallic replacement units, but there is no associated processing costs or costs for replacement cartridges.
Eramples of ESR m-ts are ASR's Silver Recovery Systems and Drew Resource Corporation 's CSR series. For less than S O you should be able to hook up a metallic replacement cartridge. Additional costs include metallic replacement cartridges, about $50 for a 5-gallon cartridge;cartridge collection and processing - $125 collection fee for a 5-gallon cartridge;and $75 for the refining fee. Recovery costs may meed silver revenue because of the small quann*ty of silver recovered. Examples of metallic replacement cartridges include Drew Resource Corporation 's Silvershure and Compliance Cartridge,ASR 's Enviro Guard Silver Recovery Cartridge,and DuPont 's Eco Guard "!
Under ideal conditions, electrolytic units reduce silver concentrations down to between 35 and 40 ppm. Under normal conditions down to 70 ppm. Metallic replacement units can lower silver concentrations to 1 ppm although 5ppm is more likely. In areas where sewer discharge limits are extremely stringent, you might achieve acceptable silver concentration levels by first passing the hypo through an electrolytic unit, and then through one or more metallic replacement cartridges. In California, publicly-owned treatment workr (POTWs) recommend two units.]
Electrolytic silver recovery units run about $700 with recycling service fees averaging approximately $150. These costs can be paid back by silver recovery and lower disposal costs.
I1 - 13 MARCH 1996
SlidesII-15, 19 Prepm-Platemaking
MATERIAL SUBSTITUTES
0 PRESENSmzED PLATES
AQUEOUS PLATE DEVELOPERS
PlatemaLing, the second part of prepress, is the preparation of a plate from a
11-17 which show a prim’ng facility employee preparing a photographic image and making a plate f” it using a b g e automane platmaking machine. As you can see, platemaking is a photographic p m e s s (like a copying machine) that tr.an@iem an image to a plate, which, in this case, is aluminum.
photographic imagt. GO to S l k 11-16 Md
Once the plate is made, it is passed through a processor which further develops and finishes (or gums) the plate. Many processors use aqueous developing chemicals. Go to Slide ZI-18 which shows this aluminum plate being passed through a processor thaz uses aqueou~ chemic& (hot solwnt-bad) that recirculate wrtil they are Spent.
[Instructors’ Note: Many printem haw inrtaued a q u e o u s p ~ p ~ i n g equimnt using presensitized plates, no-u developers and desensitiurs (gammers). Aqueowpmtssom an? W l y available and can suit any size operclton. Table-top
~~
11- 14
The primary waste generatad by platemaking
are also generated in this step once they no is spent develc?per. of course, spent plates
longer can be used.
GO to Slide II-19.
Over the past several years, developments in plates and platemaking and processing equipment have dramatically reduced the wastewater and hazardous wastes generated in this step. New and emerging
plate methods, virtuaUy eiiminate wastes. technologies, like dry imaging and direct-to-
Our discussion of platemaking will cover
presented by new and emerging technologies. Finally, we’ll address
matcriai substitutes, first, then opportunities
recycling.
MARCH 1996
” T A T I O N n: PoLLUTION VENTI ION TECHNIQUES PoLLUTION PREVENTION
TRAINING I”UCT0Rs’ GUIDE
Presensitized Plates
e Most of you probably use presensitized plates (as shown in the slides), but. if you don’t, consider switching to them. These plates are very popular in . lithographic print facilities because they generate small volumes of spent developer (usually nonhazardous) and can be reused and recycled. Make sure your platemaking equipment can process them.
Aqueous Plate Developers
e Aqueous plate developers can be substituted into your process. In many areas, they can be discharged to the sewer, thus eliminating the need to dispose of them as hazardous waste. Check with your local sewer district for applicable requirements. Most processes do not require an equipment change to use aqueous developers, and do not require the use of toxic developers. Presensitized plates and aqueous developers must come from the same manufacturer.
a Several manufacturers, such as 3M, Viking, DuPont AQ, Enco Aqua- Dev and Kodak Aqua-Image offer aqueous developers. It’s important to keep the bath solution clean to yield high quality plates.
[Instructors * Note: Aqueous and traditional chemicals cost about the same. However, aqueous chemicals need to be changed more oJien, every 15Oplates instead of every 250 plates with solvent-based developers, to ensure plate qualiry. So, the benefits associated with lower disposal costs may be reduced by higher material expenditures.]
Are there additional material substitutes that you can share! with us?
II- 15 MARCH 1996
POLLUTION PREVENTION PRESENTATION II: POLLLJTION PREVENTION TECHNIQUES T-G INSTRUCTORS’ GUIDE
~
Slide 11-20
NEW AND EMERGING TECHNOLOGIES
e ELECTRONIC IMAGE PROCESSING TECHNOLOGIES - DESKTOP PUBLISHING, SCANNERS AND DIGITAL CAMERAS
e DIGITAL PREPRESS - DIRECT-TO-PLATE, DIRECT-TO-PRESS, DIGITAL PROOFING
Preprcss
Prepress has undergone tremendous technological change with the revolution in electronic capabilities and computer chip technology.
These technologies dramatically reduce or eliminate wastes.
e Electronic image processing technologies include desktop publishing, scanners and digital cameras. These technologies, which many printers have successfully integrated to varying degrees, offer increased speed and efficiency and unlimited creative options. They also reduce or eliminate photoprocessing wastes and water use and drastically cut energy consumption.
e Digital technologies you may want to consider include direct-to-plate, direct-to-press, and digital proofing.
- Direct-to-plate technologies image a computer-generated design directly to the plate. Advantages of this technology include high digital plate quality, reduced labor costs associated with stripping, platemaking and make ready steps, reduced material costs, and no p r e p r e s s w a s t e s . D isad va n t age s include having to re-image plates that develop problems, and desktop file and color management problems.
e Digital technologies eliminate prepress waste even further than desktop publishing by directly transferring a computer-generated image to the plate.
I I - 16 MARCH 1996
m L L U n O N PREVENTION TRAINING INSIIIUCTORS’ GUIDE ~REXNTATION II: POLLUTION PREVENTION TECHNIQUES
- Direct-to-press technologies What has been your experience With these digitally image a plate on technologies? How can small and t h e p r e s s with an medium size printers afford to transition electrostatic charge. Most to these technologies? of these presses operate waterless and alcohol free, reducing the printer’s hazardous waste generation and air emissions. Other a d v a n t a g e s a n d disadvantages are similar to direct- to-plate.
- Digital proofing significantly reduces the costs of creating traditional proofs which involve high labor and materials costs. The largest cost to digital proofing is the capital investment in equipment. Kodak, 3M and others sell direct digital color proofing systems.
High investment costs is the primary barrier to each of these technologies, particularly for small and medium-size printers. Costs start at $30,000 for a system that includes computer hardware and software, scanners and expansion or add-on technologies, such as digital cameras.
[Instructors’ Note: Several references on new and emerging technologies are listed in Appendix G. Try to look at a couple of them to become more familiar with these technologies.]
I1 - 17 MARCH 1996
m L L U n O N PREVENTION pRESENTATION II: PoLLUTION PREVENTION TECHNIQUES TRAINING INSTRU~RS’ GUIDE
Slide II-21
RECYCLING ACTIVITIES
0 TONER AND TONER CARTRIDGES
0 ALUMINUM PLATES
0 PLASTIC PLATES
Prepress
Certain prepress wastes can be recycled including:
0 toner and toner cartridges used in image processing,
0 aluminum plates, and
0 plastic plates.
Many vendors will recycle toner and toner cartridges. Once they can no longer be reused, aluminum plates can be sold as scrap. Recyclers will often pay you for your aluminum plates.
You may have to pay a recycler to pick up plastic plates because their value is minimal.
II- 18 MARCH 1996
I -
-ATION n: mLLUTlON PREVENTION TECHNIQUES
Slides 11-22, 27 Press
BEST MANAGEMENT PRACTICES
e SMART MATERIALS MANAGEMENT
0 INVENTORY CONTROL
SCHEDULING AND MANAGING JOBS CAREFULLY
Now, let’s talk about the press step. In printing, the plate accepts ink from a roller and transfers it to a blanket and then to paper. Go to Slide 11-23 which shows a jive-color press operating.
Successful lithographic printing requires the press operator to be thoroughly familiar with both the press equipment and how the inks and other materials behave. Ink, fountain solution, water, substrate and press adjustment all play a role in achieving the proper image. Go to Slide 11-24 which shows establishing product quality objectives by defining an acceptable color. Go to Slide 11-25 which shows a pressman adjusting and monitoring the press and its output. These are critical steps that must be taken to avoid bad runs (Go to Slide 11-26) which are costly and generate wastes.
Go to Slide 11-27.
Pollution-related problems in press operation focus on VOC emissions from
inks, fountain solutions and cleaning agents, generation of hazardous waste ink and the environmental and employee health and safety concems associated with these emissions. Reducing and adequately managing press cleanup wastes, which present similar concems, are discussed in the next section.
Low cost BMPs can be used to reduce ink use and wastes. For example,
Keep ink containers sealed and contents leveled; place plastic or waxed paper on top of .the ink to prevent oxidation and spray ink with an antiskinning agent.
If your facility is large enough, presses can be dedicated to specific colors or to hazardous inks only, decreasing the number of cleanings needed for each press.
Use a standard ink sequence for process colors.
I1 - 19 MARCH 1996
POLLUTION h l W E W I O N PRESENTATION II: POLLUTION PREVENTION TECHNIQUES
0 Schedule runs from lighter to darker colors to decrease the amount of cleaning necessary.
TRAINING Wsmucmm’ GUIDE
Improve accuracy in job estimation.
0 Carefully monitor inventory to assure that older inks are used in a timely fashion and inks are only ordered if necessary.
0 “Prethink” printing jobs and inform customers about the environmental impacts associated with particular color, paper or printing method choices.
[Instructors’ Note: These BMPs are presented in the Iowa Waste Reduction Center publication listed in Appendix G. ]
Implementing BMPs to reduce inks or to minimize other wastes requires a commitment from facility management as well as proper employee procedures and training.
Who has experience with these BMPs? Which ones work best?
Next, we’ll cover other P2 techniques in printing including using lower VOC inks, more efficient press equipment, and recycling.
I1 - 20 MARCH 1996
PoLLUI'ION PREWNTION PRESENTATION II: P~LLUTION PREVENTION TECHNIQUES TRAINING Irvmum~s' GUIDE
Slide II-28 Press
MATERIAL SUBSTITUTES
0 VEGETABLE-BASED INKS
0 ISOPROPYL ALCOHOL (IPA) FREE FOUNTAIN SOLUTIONS
Substitutions in press operations are available for inks and fountain solutions.
0 Vegetable-based inks. These inks, including soybean and linseed oil- based, can significantly reduce VOC emissions. Soy inks have as little as less than 1 percent VOC content and are particularly useful for printers who must meet air quality agency permit requirements or who want to avoid having to get a permit triggered by a certain level of VOC emissions.
[Instructors 'Note: Soy inks are comparable in price and quality to petroleum-based inks. All types of soy inks are available, including metallic and fluorescent. Inform your customers of the quality and benejits of soy- based inks. Some soy inks may not be as rub-resistant as oil-based inks and may dry more slowly. However, many printers jind that customizing dryers and using drying powders help them obtain good results. Examples of manufacturers are Western Ink, Soya, Gam Enviroset, and Kohl & Madden Ultrasoy II. ]
as IPA-containing fountain solutions and help to reduce VOC emissions. Be sure to check if you can use IPA substitute solutions on your press equipment. You will probably have to adjust settings and watch the process closely until you are familiar with how the solution behaves (Le., there is a significant learning curve associated with making major changes. You can often get help from vendors). Examples of non-IPA solutions are Suranol-Summit Fountain Solution and Prisco Alkaless R and Q Series.
0 IPA-free fountain solutions are more expensive than IPA products. However, you will use less because they don't evaporate as much.
Indoor air quality improves by using low VOC products. Employees will be exposed to less air emissions.
What materials do you use that reduce wastes and emissions?
0 Fountain solutions that contain IPA substitutes can be as effective
I1 - 21 MARCH 1996
POLLUTION PREVENTION TRAINING IN~OCTORS’ GUIDE PRESENTATION n: PoLLUTlON PREVENTION TECHNIQUES
~ Slides 11-29, 31
EQUIPMENT MODIFICATIONS
e FOUNTAIN SOLUTION REFRIGERATION
e AUTOMATIC INK SETI’ERS
e AUTOMATIC INK LEVELERS
e INK AGITATORS
e WATERLESS PRESSES
press
Equipment modifications can often be solution is not cost efective for small made to your existing press. Most of printers.] these modifications function as press attachments, and include: Go to Slide II-31.
a Fountain soh t ion refrigeration units reduce evaporation and maximize efficiency. Go to Slide II-30 which shows a fountain solution refigeration unit designed to recirculate solution to a four color press (the unit’s covers are 08 but they should be on).
[Instructors’ Note: Non-IPA fountain solutions do not need to be refigeratedto reduce evaporation and VOCs (since there are no VOC emissions). However, printers have found that non- IPA solutions finction better when chilled to a constant temperature. Refrigeration of fountain
e Automatic ink setters reduce time and waste during the make-ready stage.
e Automatic ink levelers ensure ink is distributed evenly across the press ink tray.
e Ink agitators can be installed on the ink tray to prevent premature ink oxidation.
[Instructors’ Note: Automan‘c ink levelers can be installed on most presses, but are most appropriate for large presses. Print facilities with small presses can enciently spread the ink by hand.]
II- 22 MARCH 1996
PoLLUnON PREVENTION " T A T I O N PoLLUTION PREVENTION TECHNIQUES TW"G I N S T R U ~ R S ' GUIDE
Waterless presses are available which require no fountain solution or water, but involve a significant capital expenditure. Heat is used instead to transfer the image to the blanket. Manufactures include Water Mark Press, Thompson Litho, and Color Graphics. Equipment costs can be as high as $200,000.
[Instructors' Note: See Appendix G for references on waterless presses.]
What equipment modifications have paid off for you?
I1 - 23 MARCH 1996
POLLUTION PREVENTION PRESENTATION Ik POLLUTION PREVENTION TECHNIQUES TW”G INSTRUCTORS’ GUDE
Slide II-32 PtesS
RECYCLING ACTIVITIES
e WASTE INKS
e INK CANS
e LUBRICATING OILS
e PAPER
Most wastes generated by the press operations can be recycled.
e Waste inks are often considered hazardous wastes because of the presence of heavy metals. Waste inks should be manifested and sent to an energy recovery facility or a recycler. Very large printers,
ink, may find it cost effective to contract with a waste ink recycling firm who will arrange to recycle waste ink onsite with a certified
segregate waste ink colors prior to recycling.
generating large volumes of waste e
mobile unit. Remember to e
How many of you dispose of waste ink that is recovered as energy or recycled?
cans may prevent recycling in many areas. Check with your local recycling company to see if they willaccept these cans. Some may accept cans if they are washed and crushed. Can crushers that process 5-gallon cans and smaller cost about $1,500.
Press lubricating oils can be recycled. Any amount above a quart can be accumulated and recycled.
Most types of paper can be recycled. Separate your colored paper. Go to Slide II-33 which shows a white paper recycling bin.
e Look into recycling ink cans. However, regulatory concerns about residual ink that remains on
I1 - 24 MARCH 1996
PoLLUT'ION PREVENTION TRAINING bImUCTORS' GUIDE " T A T I O N n: POLLUTION PREVENTION TECHNIQUES
A well-operating press is critical to meeting pollution prevention goals. In addition to preventive maintenance, regular cleaning is also necessary to keep the many moving parts of the press operating. Cleaning solutions are generally petroleum-based and contain up to 100% VOCs. A single cleaner may not be the best way to clean rollers, blankets and the outside of the press.
Slide 11-34 h e S S
REDUCING PRESS CLEANUP WASTES
e PROCEDURAL IMPROVEMENTS
e SOLVENT SUBSTITUTIONS
e AUTOMATIC BLANKET WASHERS
e REUSING AND RECYCLING CLEANING WASTES
Blanket cleaning uses approximately two- thirds of cleaners applied to the press. This is because blankets must be very clean to ensure print quality. The cleaners must remove excess ink and dry quickly without leaving any residue. Solvents used for rollers should be less volatile so the solvent spreads over all rollers before evaporating.
from inks and solvents, you may be directly regulated by air pollution control authorities. In addition to VOC emissions from cleaners, other wastes include waste cleaner with residual ink and shop towels. Waste solvents must be handled as hazardous waste. Shop towels that are heavily soiled with solvent and ink may be considered hazardous wastes. However, most shop towels can be laundered or disposed of as a nonhazardous solid waste.
Pollution prevention techniques for press cleaning include:
e Procedural improvements, such as:
- Clean presses as needed, not on a schedule. But, don't let ink build up on the equipment.
Press cleaning generates VOC emissions which expose employees to toxic chemicals. Depending on your emissions
I1 - 25 MARCH 1996
PoLLUTION PREVENTION TRAINING INSTRUCTORS’ GUIDE PRESENTATION 11: POLLUTION PREVENTION TECHNIQUES
- Use a two-step cleaning approach (apply a cleaning solution with a higher VOC content as step one and immediate!y rinse with a low VOC cleaner as step two).
- Use the smallest amount of cleaner possible and apply cleaners with rags instead of pouring solvent over the parts.
- If cleaners must be poured over rollers or press parts, use a catch pan beneath parts.
Low (reduced) VOC solvents. These alternative solvents may increase cleanup time but provide the benefits of reduced VOC solvents. Follow manufacturers’ recommendations. Many low VOC cleaners tend to be water-soluble or water-miscible and often require a water rinse following application. Low VOC solvents do not dry as quickly as traditional solvents. These types of solvents have prices comparable to traditional solvents. If you have concerns about the ability of a 30% VOC solvent to clean your presses’ blankets properly, experiment with a low VOC cleaner on your rollers first. Examples of these products are Varn California Wash, Ecolo Clean, Prisco Environmental Series, and Enviroklene.
e Recycled solvents. Recycled solvents substitute for virgin products. Many vendors sell recycled solvent. Price is similar to or lower than a virgin product. Quality may be inferior depending on how you use the solvent (e.g., larger quantities may have to be Used).
e Automatic blanket washers may reduce how much solvent is used and reduce how much time is
equipment is only cost effective for large presses.
required for cleanup. This
Many cleaning wastes can be reused cost- effectively. Reuse activities include:
0 Using dirty solvents initially to cut heavy deposits, such as those that occur with varnishes. Clean solvents should be used for a final wipe down. Ensure that this method can meet your quality requirements.
e Laundering shop towels used for cleanup. Many printers aiready get
‘ their shop towels from a commercial laundry service.
[Instructors’ Note: Most laundry services will accept shop towels with residual ink and solvent, but not shop towels soaked with solvent. You should have a container for your dirty shop towels that h a a screen and drip pan on the bottom so that solvent can drain from the shop towels and collect in the drip pan below.]
I1 - 26 MARCH 19%
-ATION n: m L L U n O N PREVENTION TECHNIQUES ~ U U T I O N PREVENTION
TRAMINC " r o ~ 9 GUIDE
Recycling cleanup solvents.
[Instructors' Note: The waste solvent you generate will help you decide if onsite solvent recycling will save money or if using a vendor makes more sense. Most printers find it more cost efective to contract with a vendor. Solvent distillation units are available in direrent sizes. The smallest units can handle 5 gallons of waste solvent per batch and cost $1,500 to $3,000. Most distillation units pay for themselves well within two years because you will save money in disposal costs and in virginsolvent purchases. Of course, you need to consider some factors before deciding to install a solvent distillation unit, including the amount of solvents you use and the increased liabilities and regulatory requimments associated with onsite recycling.
If you do not recycle solvent in your facilig, you can pay a solvent recyclingcompany to come to your facility to pick up your used solvent and have it recycled. Generally, 70% to 80% of used solvent can be recovered and sold back to generators at a reduced cost.]
I1 - 27 MARCH 1996
PoLLUTION PREVENTION PRESENTATION n: POLLLITION PREVENTION TECIfMQuEs TRAINING IN~~RU~TORS’ GUIDE
Slide 11-35 Postpress
REDUCING AND RECYCLING POSTPRESS WASTES
LOWER VOC AND LESS TOXIC GLUES
WHITE PAPER
COLOR PAPER
CARDBOARD
Postpress includes binding and finishing. Printers apply glue and other binding materials (e.g., plastic spiral) to the products. Finishing involves any trimming that may be necessary. For example, when printing posters, there is usually some excess space on the margins that must be trimmed.
The primary wastes generated in postpress are paper trimmings and waste glue. Many glues generate VOCs. Of course, binding machines use electricity.
0 Talk to your vendors and review material safety data sheets to identify lower VOC and less toxic glues that will work for you.
0 All types of paper and cardboard can be recycled.
I1 - 28 MARCH 1996
mLLUTION -ON PRESENTATION mLLUTION -ON Tw”G ~ ~ ~ R U C T O R S ’ GUIDE
Slide III-1
PRESENTATION III
IMPLEMENTING POLLUTION PREVENTION
m - 1 MARCH 1996
slide III-2
FOUR STEPS TO POLLUTION PREVENTION
COMMIT TO POLLUTION PREVENTION
ZDEhl7FY POLLUTION-RELATED PROBLEMS AND P2 OPPORTUNITES
SELECTPOLLUTION PREVENTION TECFINIQUES
IMP- AND MONITOR TECHNIQUES
In order to implement pollution prevention techniques, follow t h e four simple steps:
1) Commit to pollution prevention.
Customers want a quality product at a reasonable cost (even though many will be willing to pay a little more for a product that helps p r o m the environment).
Since pollution prevention techniques may involve modifications to your operations, support and commitment from owners and managers are needed. Employees also need to understand the benefits associated with pollution prevention and support related
customers about products that employ P2 and their benefits is critical to implementing P2.
operational changes. Also, informing your
Owners, managers, employees and customers are motivated to support P2 in somewhat different ways.
For instance, owners may be concerned most with the bottom line while employees may care most about health and safety issues and having a manageable workload.
The key to implementing P2 is finding solutions that create win-win situations for everyone.
2) Idesltify pohtion-related problems you want to address and associated P2 opportunities based upon a review of facility activities.
3) Identify, evaluate and select appropriate pollution prevention techniques. In general, the following business factors should be considered in
Thcsefactorscanbeconsidered pros and selacting pollution prevention techniques.
cons for P2 techniques:
technicalfeasibility equipment and material costs
m - 2 MARCH 1996
labor costs waste management costs training efforts permit requirements health and safety issues product or seMce quality environmental benefits annual cost savings and period (ifapplicable)
a remember, source reduction should be prioritized over recycling and reuse.
4) Implement the techniques and monitor their effectiveness.
Get help from trade assoCiations and other organizations (e.g., government technical assistance programs) and keep abreast of new developments.
m - 3
Slide III-3
POLLUTION PREVENTION EXAMPLES
Now WS practice what we’ve learned about f i r P2 ispmbablyp@m2de. Ifyou choose pollution prevention by discussing a few to use your own cwmples, ask your examples of pollution-related problems and audience earlier in the worRshop @.e.’ at opportunities for P2 associated ’ withfacility besinningqf- * n U) W h pmblems activities. c o w m them and then develop your
GxrrmpIGs with this input in mind.] The examples are:
Inventory control, and
Press cleanup wastes.
[Instructors’ Note: Disnibute pollution prevention examples and $bur copies of the checklist to each wonkrhop partici@ant. Use the instructors’ notes to fmYitate a gmup discussion on i&m!ing pollution-related p m b h and oppomuaitiesfir P2 assm‘ated with the examples. For your convenience, business fmors are highlighted for each possible P2 technique. Foclrr on pmenting the fact sinrarion and asking the qucstiolls, look to your audience f i r potential techniques and pms and cons. Use your inmrcctors’ notes only QT ne& to faelitate the discursion. Although these examples are probabty appropriate for most oudienccs, developing your own Gxomplcs based on your audience’s problems and oppomrnitics
m - 4 MARCH 1996
I .
Slide III-4
POLLUTION PREVENTION CHECKLIST
FOCUS ON P2 " I Q U E S THAT ADDRESS POLLUTION-RELATED PROBLEMS
CONSIDER BUSINESS FACTORS
We'll use a simple checklist as a tool.
The checklist can help you select the best P2
problems and opportunities for P2 you've identified. It is a tool to help you evaluate pollution prevention techniques by looking at a range of business factors.
technique to address the pollution-related
Check off the factors that are important. The checklist provides an area to write down the problems and opportunities you are addressing. Determine which business factors may apply and make notes as necessary.
m - 5 MARCH 1996
POLLUTION PREVENTION TECHNIQUEREVIEW CHECkLLIsT
POUUTION-REI,ATED PROBLEMS:
BUSINESS FAmORS TO CONSIDER FOR EACH POTENTIAL TECHNIQUE:
TECHNXCALFEASIBILITY:
EQWh4ENT AND MATERJALS COSTS:
LABOR COSTS:
WASTE MANAGEMENT COSTS:
TRAINING EFFORTS (for new procedures):
PERMlT REQUIREMNTS (new or modified pennit or "y -t):
PRODUCI' OR SERVICE QUALITY:
ENVIR0"TAL BENEFlTS (reduced raw rmtsri.ls oonsumption, hazardow rrnd solid waste gmeration, e.):
ANNUAL COST SAVINGS (annual cost of curreat pr;rctice minus annual pmject c a b ) ~~
PAYBACK PERIOD (apitd project cos& divided by expected annual savings): ~
WHICH TECHNIQUES CAN BE IMPLEMENTED IMMEDIATELY?
WHICH REQUIRE MORE INFORMATION?
WHICH ARE PROBABLY NOT PRACIICAL?
I D - 6 MARCH 1996
This lithographic printer, with 10 employees, has two offset prcsses. Photoprocessing is done in-house. The company uses aqueous plate processing equipment. Employees have open access to materials, including cleaning solvents, photoprocessln ' g solutions, and inks. Inks purchased are premixed and o r d d monthly based on a rough estimate of needs. Ink and solvent containers, as well as photoprocessing baths, are often left uncovered. The facility owner is concerned about high materials use, particularly expired ink that quires disposal, and increasing costs for solvent disposal.
what are the pollution-related problems associated with this example?
1. High materials use because of open access to supplies and imprecise estimating procedures.
2. Significant hazardous waste disposal costs because of high materials use and expired ink.
3. Increased VOC emissions and impacts on employee health and safety and regional air quality because of uncovered containers and baths.
What are the potential P2 techniques that could address these problems? (taken in order by problem).
1. Implement a proper inventory control system including "prethinking" matentslls needs, mixing inks onsite or ordering them based on more accurate estimates, using a tracking system, assigning an individual to control access to materials (See pages II-7, 8, 19 and 20 for more ideas and specific information).
2. Inventory control will help reduce materials use and, therefore, waste
g- . . Also, waste ink and solvent generation can be reduced by using less hazardous matcrhk and increasing process efhciency (e.g., scheduling runs from lighter to darker colors to decrease the amount of cleaning necessary).
3. Cover containers and baths to reduce emissions (See pages IC-8, 9, and 18).
Business faders that should be considered to evaluate each technique (taken in order):
1. Materials costs (savings from reduced ordering, increased costs from ordering in smaller quantities, no bulk discount).
Waste disposal costs (savings from reducing amount of expired and wasted materials).
Labor costs (increased time to cioSely track materials needed).
2. Matcnals . costs(savingsfromreduced ordering, increased costs from ordering in smaller quantities, no bulk discount).
Waste disposal costs (savings from reducing amount of expired and wasted IIlaterialS).
III 7 MARCH 1996
Labor costs ( i n d time to c l d y track materials needed).
product quality (negative impacts that could result from using alternative materials) . Training costs (to train employees on use of alternative materials).
Materials costs (potentially i n d costs of alternative materials).
Waste disposal costs (savings from reduced amounts generated).
3. Mate&& costs (reduced materials needs because of less evaporation, spiils).
Labor costs (minimal, if any, costs for properly c o v h g contain-).
Equipment costs (minimal costs for installing covers and lids on photoprocessing solutions).
Health and safety (less employee exposure to VOCs).
m - 8
This pMter, with 25 employees, has four offset presses. The facility uses a petroleum-based cleaner with a 90% VOC content to clean both blankets and rollers. This printer generates a volume of emissions that the local air pollution control district is considering regulating. The printer's employees have complained d o n a l l y about exposure to VOCs and heavy odors from solvents and ids.
What are the pollution-dated problems associated with this example?
1. Local air district is considering regulating this facility.
2. Employees are concenred with exposure to VOCs in the press room.
What are the potential P2 techniques to these problems? (taken in order by problem).
1. Use a lower VOC cleaner for rollers or a lower VOC cleaner for both rollers and blankets.
2. Implement procedural changes: use the smaUest amount of cleaner possible; use catch pans under the press parts; and a two step cleaning approach (applying a cleaning solution with a higher VOC content as step one to be immediately rinsing with a low VOC cleaner as step two).
[Each of the above techniques addrtsses the two pollution-related problems].
Business factors that should be considered to evaluate each technique (taken in order):
1. Materials cost (low VOC washes are slightly more expensive).
Labor cost (more time required to wash presses, increased drying time).
Permit requiremeats (may eliminate need for air permit).
Training (employee training needed to we low voc washes).
Health and safety (reduced exposure to emissions).
Waste disposal costs (no significant change, still handled as hazardous -1.
2. Materials cost (lower costs because less product we).
Labor cost (more time to implement procedural changes).
Permit requirements (may eliminate need for air pennit).
Training (employee training and supemision needed to implement these techniques).
Health and safety (reduced exposure to emissions).
waste disposal costs (lower because of reduced use of cleaners).
III-9 MARCH 1996
Do you know more about pollution e
approach and three to five specific ideas to
you can make a difference. To make sure 0
prevention, keep the following pollution e
prevention? Did you identify techniques you can use right now? Take our four-step
prevent pollution back to work and see if
that you get the most out of pollution
prevention principles in mind:
e
slide m-5
SOLUTIONS THROUGH POLLUTION PREVENTION
BE COMMITTED
IDENTIFY POLLUTION-RELATED PROBLEMS AND P2 0 P P O R " T E S
SELECT POLLUTION PREVENTION TECHNIQUES
IMPLEMENT AND MONlTOR TECHNIQUES
TRAINANDMOTIVATEEIKPLOYEES
INFORM AND EDUCATE CUSTOMERS
Identify, evaluate and select techniques;
Implement and monitor techniques;
Train and motivate employees; and
Inform and educate customers.
Be committed to pollution p e n t i o n ;
Identity polhrtion-related problems you want to address and ZLSSOCiatCd P2 opportunities;
m - 10 MARCH 1996
APPENDIX B
LIST OF TEXT AND PaOTO SLIDES
MARCH 1996
LIST OF TEXT AND PHOTO SLIDES
Presentation I
Slide 1-1 Slide 1-2 Workshop OvervieW Slide 1-3 Slide 1-4 Why Pollution Prevention? Slide 1-5
Introduction to Pollution Prevention
What is Pollution FVcvention?
Your Commitment to P2
Presentation 11
Slide 11-1 slide 11-2 Slide 11-3 Slide II-4 Slide. 11-5 Slide 11-6 Slide 11-7 Slide 11-8 Slide 11-9 Slide IX-10 Slide 11-11 Slide II-12
Slide 11-13 Slide 11-14 Slide 11-15 Slide XI-16 Slide 11-17
Slide 11-18
slide 11-19 Slide 11-20 Slide 11-21 slide 11-22 Slide 11-23 Slide 11-24 Slide 11-25
Pollution prevctltion Techniques for Lithographic Pxintas overview Printing steps Inventory Control Printer’s ink inventory (photo) Inventory Cmtrol (repeat of slide II-4) Proper containment of acids (photo) Proper containment of flammable matuials (photo) Inventory Control (repeat of Slide II-4)
Large, “ a b l e and refillable containers of photoproccsshg chemicals (photo) prepress-lmage- ’ g, Best Management Practices and M a W s Selection (repeat of Slide 11-10) Prepress - lmage Proccssrn * g, Equipment Modifications An electrolytic silver recovery unit (photo)
A printing facility employee Preparing a photograshic image (photo) Making a plate from a photographic image using a large automatic platemaking machine (photo) Aluminum plate being passed through a pnxxssor that uses aqueous chemicals (not solvent-based) that recirculate until they are spcnt (photo)
P ~ ~ ~ R s s - Image m g , Best Management Practi- and Materials Selectian
Prep= - Platemaking, Material Substitutes
prepress - P l a t ” ’ g, Maklid Substitutes (repeat Of Slide Il-15) Prepress - N w and Emerging TeChn010gi~~ PrcPreJs - Recycling Activities Press - Best Managemcat Practices A five-color press operating (photo) Establishing product quality objectives by defining an acceptable color (photo) A prtssman adjusting and monitoring the press and its output (photo)
B - 1 MARCH 1996
c
mLLVTION -ON A??ENDIx B Trummc bisntumo~S’ GUIDE
Slide 11-26 Slide 11-27 Slide 11-28
An example Of bad ~IIU Which Press - Best Management Piactices (repeat Of Slide 11-22) Press - Material SubstitUtes
costly and generate wastes (photo)
- Slide 11-29 Press - Equipment Modifications Slide 11-30
Slide XI-31
A fountain solution refrigeration Unit designed to fecifcufatt solution to a four color press (photo) Press - Equipment Modifications (repeat of Slide 11-29)
Slide 11-32 Slide II-33 Slide 11-34 Slide 11-35
Press - Recycling ActivitieS A white pa~er mycling bin (photo) Press - Reducing Press Cleanup Wastes Postpress - Reducing and mycling Postpress Wastes
Presentation 111
Slide III-1 Implementing Pollution prevesltion
Slide III-3 Pollution Prevention Examples Slide III-4 Pollution Prevention Checklist
Slide III-2 FOW Stcps to Pollution Prevention
Slide III-5 SOlUtiOnS through Pollution Prevention
B - 2 MARCH 1996
Lithographc - Prrters
0
Pollution pnvontion is g o d businoss Pollution prevention or P2 is about generating less waste and pollutants and increasing efficiency. P2 cost-effectively solves many pollution-related problems associated with waste generation, discharges, and emissions. Every printer employs some of the pollu- tion prevention techniques that are discussed in this fact sheet. Printers may refer to these techniques simply as “good business practices” or “standard operating procedures.” Some may know them as waste reduction or waste minimization. Although this fact sheet focuses on lithographic printers, most of these techniques also apply to other types of printers.
What is pollution pnvontion3 P2 is the use of materials, processes, or practices that reduce or eliminate the generation of pollutants or wastes at the source. Included in this definition are practices that reduce the use of materials, energy and water, and practices that, by improving efficiency, indirectly protect natural resources. P2 differs from wuste reducrion or wuste minimizu- tion in that it looks at all types and sources of pollution, not just solid and hazardous wastes. Although reuse and recycling are not technically considered pollution preven- tion, if conducted in an environmentally safe manner, they offer many of the same benefits. P2 is a regulatory program; it is usually completely voluntary.
Why should you bo intorustod in pollution provontion?
Reduce materials use and costs, Cut waste disposal costs, Improve operations and efficiency, Heip you comply with environmental regulations, Minimize wastewater discharges and air emissions, and Reduce liability and associated costs.
v :
Pollution pnvontion in lithographic printing Pollution prevention techniques apply to your facility’s general operations and each step of the printing process including prepress, press and postpress. These techniques involve using fewer toxic materials, installing quipmcnt that increases efficiency by reducing raw materials use and waste, and reuse and mycling practices.
Making changes in your facility requires the understanding and commitment of managers and employees. Therefore, the techniques described below should be implemented with a program to inform, train and involve all employees.
Also, tell your customers about the environmentally friendly materials that you have available. For example, inform customers about the availability and quality of soy-based inks and recycled paper. Display examples of finished products made with these materials. Customer interest in these “green products” and pollution prevention may surprise you.
Facilii Op.mtionr Conserve energy by using energy-
e
Segregate wastes to increase recyclability . Keep careful records of inventory. Implement a “first-in, first-out**policy of chemical product use. Do not order more than can be used within the shelf life of the product. Labels and expiration dates should be legible. Designate one person to manage raw materials for proper inventory control and to ensure that hazardous substances are properly contained and labeled and that a Material Safety Data Sheet (MSDS) is on file. Minimize spills and use dry methods for cleanup wherever possible. If a spill of a hazardous substance occurs, use a rag or an absorptive material to soak it up and dispose of it in accordance with all local, state, and federal regulations. Be innovative in trying new procedures and products, including recycled paper with a high post-consumer content. Find ways to reuse paper. Make notepads, poster-paper, or other prod- ucts from extra paper. Recycle all paper waste or donate it to schools and churches.
efficient lights and equipment and turning them off when not in use. Conserve water by installing water- saving devices, reusing water and using only what you need. Your local utilitylwater purveyor may offer free energy and water conservation audits.
Pw-U Use computers to set up and edit jobs to produce proofs for client approval. This technique reduces photoprocessing wastes because “soft proofing” on a computer is possible. Employ photographic intensifiers that don’t contain mercury or cyanide salts. Use silverless films, such as electrostatic films, that have speeds and resolution comparable to silver films.
chemical changeouts by monitoring bath solutions closely. Install automatic wash baths which save water and reduce waste by turning on washwater only when film is being processed.
Reduce unnescssary photographic
a
a
a
Use squeegees or rollers between baths to remove residual fluid from the film befort it is placed in the next bath. This prevents bath contamination and reduces material use. Employ silver recovery units “in-line” to extend the life of the developer and to help meet wastewater discharge limits. This may only be feasible for larger printers. Contract with a hauler to send used film and film scraps, developer, and recov- ered silver offsite for silver recycling. Use presensitized plates that only generate small volumes of spent devel- oper (usually nonhazardous) and are reusable. Employ aqueous platemaking to d u c e or eliminate the use of hazardous developers and fixers. You may be able to discharge wastewater from the aqueous process directly to the sanitary sewer. Consider new prepress technologies like electronic image processing (e.g.: desktop publishing, digital cameras,), direct-to-plate, direct-to-press and digital pmofmg to reduce or eliminate prepress wastes.
P” a
a
Maximize use of vegetable-based and ultra violet inks that significantly reduce or eliminate VOC emissions. Soy-based inks with 1% VOC content are avail- able. These inks reduce air emissions and improve workplace safety. a
Select inks that minimize the use of metallic pigments. Try fountain solutions that don’t contain isopropyl alcohol (PA) to eliminate or significantly reduce VOC emissions and minimize employee exposure to toxics. Use low-VOC and citrus-based sol- vents that generate less air emissions.
Buy recycled solvents. They cost about the same as virgin solvent and may work as well for many uses. Install an automatic ink leveler to ensure that ink is evenly distributed in the ink fountain or my. Gang print or run similar jobs simulta- neously to minimize waste generation between cleanup and starting the next run. Look into waterless presses which require no fountain solution or water. Refrigerate fountain solution to maintain solution concentration by reducing evaporation or volatilization. VOC emissions are reduced. This may not be practical for smaller printers. Use hot parts washers or solvent sinks to clean removable parts. Ask for non- chlorinated solvents if you use sinks. Use dirty solvents or lower VOC cleaners for initial wipe down of press equipment, followed by final cleanup using a higher VOC solvent. Launder shop towels. Clean towels are obtained from the laundry service. Purchasing new rags is reduced. Note that laundry services may not accept rags that are heavily contaminated. These rags may be considered hazardous wastes. Use excess ink which has not been “on the press” for future jobs, or mix it together to create a “shop black.” Recycle ink. If possible, purchase inks from a distributor who will take or buy back unuscd inks. Recycle press cleanup solvents. If you use large amounts, an onsite recovery unit may be practical. Find a recycler for press lubricating oils. These wastes are often collected by recyclers that handle your solvents.
I 1 Pollution pnvontion stmpr
1. Commit to pollution prevention. Nothing will happen without your commitment. techniques.
2. Identify pollution-dated prob lems you want to address and associated €2 opportunities based on a review of facility activities.
3. Identify, evaluate and select appropriate pollution prevention
4. Implement the techniques and monitor their effectiveness.
C o r lron idornation CAL EPA, Department of Toxic Sub- stances Control (DTSC). The DTSC can provide published information on pollution prevention in your industry, potential sources of funding, and permitting require- ments. Call DTSC at (916) 322-3670.
Trade Associations. Trade associations, like the Printing Industries of America (PIA), are often a source of infonnation on new procedures, equipment and products, environmental permitting and pollution prevention. Call PIA at (703) 519-8100.
Sales Representatives. Product and service suppliers often have infomution on alternative products, services and equip ment. Ask your suppliers.
PRACTICAL POLLuTlON PREVENTION TECHNIQUES FOR LITHOGRAPHIC PRNIERS, U.S. EPA REGION IX AND CALIMlRNIA
DEPARTMENT OF TOXIC SUBSTANCES CONTROL, APRIL 1994
MARCH 1996
Practical Pollution Prevention Techniques for lithographic
- Printers
Aprii 1994
CdifomiaEnvhmmental Protection Agency Depndmeat dToxic s u w control
Submitted by:
sdeace Applications InterMtid C O ~ r a t i O a
DCN: Tz4-R0905dRN-M21O18
PRACTICAL POLLUTION -ON TECENIQW MIR L,I"HOGRAPBICPRIINTERS
Submitted To:
U.S. ENVIRONMENTAL PROTECTION AGENCY REGION IX
75HAWrHoRNEsTREm SAN FRANCISCO, CA 94105
CALIMlRNIA E"MENTAL PROTECTION AGENCY DEPARTMENT OF TOXIC SUBSTANCES CONTROL
REGION 2 700 HEINZ STREET, BulLDING F
BERKELEY,CA wno
Submitted By:
SCIENCE APPLICATIONS INTERNATIONAL CORPORATION TECHNOWGY SERVICES COMPANY
SAN F'RANCISCO, CA 94111 20 C" STREET, SUITE 400
EPA CONTRACT NO. 68.W9-000S EPA WORK ASSIGNMENT NO. R09056
SAXCITSC PROJECT NO. o66075-03-4423
TABLE OF CONTENTS
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.0 blTRODUCTION ......................................... 1 1.1 Overview of Lithographic Printing ......................... 2 1.2 Approach ........................................ 3
2.0 P O ~ U ' I ' I O N p R E ~ O N T E C M Q ~ ........................... 5 2.1 Pollution Prevention Techniques in Image processln ' g . . . . . . . . . . . . . 7
Technique No . 1: Monitor solutionslrcduce changeouts . . . . . . . . . . . . 8
recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Technique No . 3: Recover silver from fixer solution offsite . . . . . . . . . 10
containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Technique No . 5: Install squeegees between baths . . . . . . . . . . . . . . . 12 Technique No . 6 Install water recirculation units . . . . . . . . . . . . . . . . 13 Technique No . 7: Photoprocessor standby options . . . . . . . . . . . . . . . 14 Technique No . 8: Install water control unit .................... 15
2.2 Pollution Prevention Techniques in Platemaking . . . . . . . . . . . . . . . . . 16 Technique No . 9: Aqueous platemaking ...................... 17
2.3 Pollution Prevention Techniques in Printing . . . . . . . . . . . . . . . . . . . 18
Technique No . 2: Recover silver from fixer bath onsite by electrolytic
Technique No . 4: Keep lids and covers on photoprocesskg chemical
Technique No . 10: Refrigerate fountain solution . . . . . . . . . . . . . . . . 19 Technique No . 11: Control ink and solvent inventory . . . . . . . . . . . . . 20 Technique No . 12: Install automatic ink levelers or use antiskinning
Technique No . 13: Use alcohol-frec fountain solution . . . . . . . . . . . . . 22 Technique No . 14: Substitute low VOC soybean oil inks for petroleum-
basedinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Technique No . 15: Launder rags used in cleanuplobtain rags from a
launderer .................................... 24 Technique No . 16: Use an automatic blanket wash and other cleanup
attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Technique No . 17: Use low VOC press washes and cleaners . . . . . . . . . 26 Technique No . 18: Recycle waste solvent .................... 27 Technique No . 19: Use a solvent sink for parts cleaning . . . . . . . . . . . 28
spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
APPENDICES
A
B TECHNICAL. ECONOMIC. AND ENVIR0"TAL CHARACTERISTICS OF PRODUCTS COMMONLY USED IN THE L~~HOGRAPHIC PRINTING INDUSTRY
Acknowledgements
The authors would like to thank the individuals who supported the development of this publication. Several members of the printing industry contributed ideas and comments including
Jim Richards, Printing Industries of Northern California; Patrick Doyle, Abbey Press, Oakland,
California, Rod Fite, Printability, San L", Calif-, Susan Joyce, Joyce Printing, Albany, California, Michael Nelson, Custom Color Lab ( p h o t o p " ) , San Francisco, California; and Walton Chang, Golden Dragon Press, San Francisco, California. Special thanks goes to Greg
Hernandez, Williams Lithograph Company, San Francisco, California for Serving as our sample
printer to help evaluate the pollution prevention techniques discussed in this publication. The
authors would also like to thank Mf. William Wilson, Pollution Prevention Coordinator, U.S. Environmental Protection Agency, Region E, and Mr. Mark Somalis, California Environmental
Protection Agency, Department of Toxic Substances Control, Region II, for their direction and support in managing this effort.
M d Pollution Prevention Techniquw for Lithographic Printem
1.0 INTR0DUC"ION
This publication gives the lithographic printing industry an easy-muse reference for practical
information on pollution prevention techniques, tcchnologk, and clean products (hmafter
referred to as techniques) that apply broadly within the industry.
Every printer employs some of the pollution prevention techniques that are discussed in this publication. For years, printers simply r e f d to these measures as "good business practices"
or "standard operating procedures. " Some printers may know them as waste reduction or waste minimization.
Pollution prevention is an effective strategy to comply with environmental requirements and reduce costs in the lithographic printing industry. The US. Environmental Protection Agency
defines pollution prevention as "the use of materials, processes, or practices that reduce or
eliminate the generation of pollutants or wastes at the source." This document includes reuse and environmentally sound recycling in its definition of pollution prevention.
Aside from the environmental benefits associated with pollution prevention, the techniques
discussed help printers address envh"ental compliance requirements and reduce costs and
liabilities associated with their business. For example, although substituting soy-based for
petroleum-based inks is presently customer driven, in the future it will help printers comply with
air quality requirements. The silver rccoyery techniques described will help many printers
comply with sewer discharge requirements and conserve valuable silver. Certain measures, like
water reclamation, wiU reduce water and energy consumption and associated costs.
Lithographic printers were selected as the focus of this project because of the potential benefits of pollution prevention to the industry. For instance, because printing is a very competitive industry that generates several regulated waste streams, every printer would benefit from the cost
1
practical Pollution Prevention Techniques for Lithographic Printera
savings associated with implementing pollution prevention techniques. In addition, because most lithographic printers have similar processes and wastes, the techniques described in this publication would benefit the mjority of printers. This document is targeted for the largest
than larger operations and, t hmfm, could gain the most from the infarmation provided. The
pollution prevention techniques contained in this document take into consideration that equipment and processes vary between small, medium, and large size printers. Regulations that differ
based on the size and geographic location of the printer, oftcn changing the economic viability
group of printers, those having fewer than 25 employees. SmaJlerprinters have fewer raollrccs
of the techniques, are also evaluated.
The following sections provide a brief oveTview of lithographic printing, describe the approach taken to develop this document, and prescnt pollution prevention techniques.
1.1 overview of Lithographic Printing
Lithographic printing is used for commercial literature, books, catalogs, maps, greeting cards,
letterhead stationery, business forms, checks, labels, and posters. Lithographic printers
constitute the majority of the printers in the United States. Lithographic printers generate solid
and hazardous wastes, wastewater, and air emissions during the printing process.
The lithographic printing process involves three stages: image processing, platemakin g, and printing. Appendix A presents a thorough summary of the printing process. The printing process is sequential from image procesSing through printing. Image pn>cessing pioduces developed film from which press plates are prepared. The platemaking process uses the developed film and Various procesSing solutions to imprint the film image onto the plate. The
printing stage ref- to all that occurs on and around a printing press. In this stage, the developed plate is run through the press and the image on the plate is offset to a blanket cylinder
&ugh a combination of ink and fountain solution which transfers the image to another surfkc ,
2
Prscticd Pollution Prevention Technique8 for Lithographic Printers
such as paper.. After a print job is completed, the press is cleaned with blanket washes and
solvents to remove residual ink. Within each stage of the pnxxss, printers have labor,
equipment, raw material, energy and water, and solid and hazardous waste management costs.
1.2 Approach
The approach used to develop this publication involved defining practical pollution prevention
techniques based on interviews with several printing industry experts in the San Francisco Bay
Area, researching published sources and product information, and gathering information from
printers on the use, practicality and benefits of such practices.' Specifically, the following steps
were taken:
1) Published sources on pollution prevention in the lithographic printing industry were
reviewed. These included several assessment and technology guidances, case studies,
and a recent survey conducted of lithographic printers in San Francisco. The survey's
focus was to determine the range of pollution prevention techniques currently employed
by printers.
2) Product information was gathered from manufacturers of photoprocessor equipment,
platemakers, and press manufacturers. Material Safety Data Sheets (MSDS) were
reviewed for these products to determine their hazardous and toxic characteristics.
MSDSs for products advertised as "environmentally sound" w e n reviewed as well as MSDSs for other products commonly used by lithographic printers. A summary of product data is in Appendix B.
Williams Lithograph Company of San Francirco waa a primary source of information by volunteering to have a pollution prevention auesrmtnt performed at its facility.
3
Practicll Pollution Prevention Techniques for Lithographic Rinwr
3) Interviews were conducted with five experts in the lithographic printing industry to establish an industry amscnsus on a wick range of practical pollution prevention
techniques. The objective of the interviews was to develop a profile of a printer that would incorporate pollution prevention techniques and sti l l maintain (or increase) its profitability. Four of the exputs are owncdopemton of lithographic print shops in the
San Francisco Bay Area. The fifth expert is an operations manager for a
photoprocessing lab. This expert was chosen because of his extensive knowledge in
waste minimization for the p h o t o p d g stage of printing.
4) A pollution prevention assessment was perfarmed at a ~thographic printer. This printer’s processes and operations are typical of those found at most lithographic printers. The assessment gathered more information on the nature, and costs and benefits of pollution
prevention techniques identified by the industry experts. The main objective of the
assessment was to determine if the pollution prevention techniques are practical in terms
of economic, technid, and regulatory considerations.
4
Practical Pollution Prevention Techniques for Lithographic Printera
2.0 POLLUTION PREVENTION 'I'ECHMQUES
The pollution prevention techniques are organized by each stage of the printing process: image
processing, platemaking, and printing. This Section contains an exhibit for each technique that provides information on the applicable waste stream, the nature of the technique, the expected
waste reduction, technical and economic considerations, effects on product quality, employee
safety considerations, regulatory requirements, releases to other media, and the technique's
environmental benefits. Because each facility is Unique and technologies are rapidly changing,
printers who use this information should further evaluate the pollution prevention techniques with
rcspect to the above factors to determine the feasibility of the technique for their operation.
The pollution prevention techniques were chosen based on their practicality for small to medium
size businesses, their proven effectiveness, and availability. Techniques were not included if
they were found to be unavailable or impractical. Certain techniques not addressed in this document may be promising in the future. For example, additional research and development
on citrus-based terpene cleaners and silverless films will likely makc these techniques more
practical. Onsite solvent recovery is another option, but the capital costs associated with recovery equipment and regulatory compliance may limit use of these systems for most small
printers.
In addition to the pollution prevention techniques Specifically discussed in this section, several
other easy and low cost measures can be incorporated into the daily activities and pollution
prevention program of any shop. Awareness campaigns, training, good housekeeping practices
and inventory control should be an integral part of a facility's waste management program.
Employees should be well informed about environmental impacts related to the types of
chemicals used in daily operations, the minimum quantities of chemicals required to perform a job, and proper disposal procedures or recycling alternatives. Recycling many solid wastes that
5
Practical Pollution Prevention Techrtiquea for Lithoorsphic Printem
are now disposed of is possible. For example, bindery paper and other papa waste and
aluminum plates can be picked up by a solid waste or metals recycler.
Encrgyandwatercoxls” ‘on also play a significant role in pollution prevention. Energy consemation reduces the necd to construct additional power plants which are major sources of air and water pollution. Water a“mtI ‘on is important for protecting ground and surface water
resources. The amount of water printers usc increases the quantity of wastewater discharged
which may burden wastewater treatment plants, degrade water quality and impact sensitive
aquatic habitats, such as wetlands. Currently, manufacturers of image processors, platemakers,
and presses sell equipment that “izes the amount of energy and water used. Manufacturers can be contacted to inquire about whether retrofitting older machines with energy- and
water-saving features is possible. ”his section addresses these and other suggestions for reducing energy and water use.
Shop management must be committed to pollution prevention, and pass on this commitment to
employees by training and awareness building programs. Training is key to successful pollution prevention implementation. Management should provide employees with training programs and
allow them the time to learn new processes and procedures, and try new materials. Managers should be aware that pollution prevention techniques may increase the time required to conduct
a specific activity, such as press cleaning with a low VOC solvent, but that the increased labor cost may be offset by improved working conditions and savings in air quality regulatory compliance costs. Management should be willing to provide incentives to employees to implement the pollution prevention techniques discussed in this publication and to identify and
develop other techniques.
6
Practical Pollutim Prevention Tschniquw for L i t h ~ h i c Printem
2.1 Pollution Prevention Techniques in Image hcessing
Pollution prevention techniques in the image processing or photoproassing stage fall into two
categories: those techniques that extend chemical and wash bath life, and those that target, reduct, rccovef and recycle the silver in the fixer bath solution. The techniques in both
categories offer cost savings resulting from decreased labor time, material purchases, energy
use, and hazardous waste disposal. The techniques on the silver-bearhg fixer solutions, in
addition, offer potential revenue to the print shop from the value of the recovered silver.
Most of the image processing techniques require capital expenditures, but these investments are generally quite limited. The cost savings asouatd * with certain measures should make the
payback period for the capital expenditure relatively short.
Over the next few years, image processing technology is expected to change radically.
Manufacturers of image processing equipment and materials are developing technologies to
eliminate silver halide from the process and to process the image in a dry environment. (Xerox
recently announced an image procesSing system that does not use silver halide film and occurs in a dry environment.) In the future, these types of processes may become standard image
processing pollution prevention techniques.
Pollution Prevention Techniques Nos. 1-8, which are listed below, present the measures for
image processing.
1. Monitor m 1 u t i d e cluagamn 2. 3. 4. 5. InstaIl squeegees between bntbs 6. Instrll water rccircuI8tion units 7. -oEnadby options 8. Instrll water contro1 unit
Recover dver from fixer bath onsite by electmIytic recovery Recover silver from fixer solution ofbite Keep Lids and covers on photoproassln ’ g chemical containers
7
Practical Pollutim Prevention Techniques for Lithographic Printem
image h a s s i n g
Economic: savings on developer rad fixex chemical costs. No capital a+” is required. This technique m y incruse employee tims for monitoring but may reduce labor time for performing ChUgeQuts.
Eff*.
ProductQuality: None.
Employee Safety: Raiuca the number of chaugdrep1”mt rate md, thus, employee ~ o f m d a x p o c n r r s t o ~ * g &mials.
permit modificationnmy be rsquired. Regulatory Requimnmts If direh.+pa chmgss (i.e., inueaed f l o w / a “ t ~ ‘om), a permit or
8
Expccrcaw~- u p t o 9 5 % 0 f ~ l o d h r a r m d ~ f i x e r s o l u t i o n . Dcscriptioa: Silver recovery can be performed onsite by instdhg an dsctrolytic silver recovery
(ESR) unit. ESR unit COllf igUntioOl~ either termid or rscircul.tm * g. Terminal units M locrtbd OUQide of the fixex bth OIL the fixer bth averflaw line. solution p 8 S S G d t b U g h 8 b d d ~ t b s c o m e r 8 ~ . A m * g unib p l d either in the fixer bth solution within the photoprocessor unit or on li closed loop system outside the photoprocessor, removes silver from the fixer bath. A recirculating ESR prolongs the life of the fixer bath by reducing the silver ccmceatration and reduces the fixer replcainhmat rate by 6090%. A usminrl or m5" . g u n i t c a n h a stationary or rotating cathode. Periodically, indepeadeat of the option used, the silver is scraped off the ESR unit's cathode md collected for pickup by 8 metals recycler or l i d hauler. Examples of ESR unib am ASR's Siiwr Recowry Systm and Dmv R u o m corpOrations's CSR seriu.
Feasibility:
Technical: ESRs typ idy remove 90% of silver. Up to 95% m y be wailable under i d d cowlitions md ktchprocsssing. Replumbingh r e q u i d to hookup an ESR unit. A
maintenance because it has m moVingputsthrnastatioLlliycrrthode. A terminal ESR must be W e d up by 8 metallic replrccmtnt cartridge in order to meet 5 ppm
ror8tiflg athode removes more silver (becuure of eolution 8gitrtim) but requires more
("um) fedend limit ford- to mwcr.
Economic: Cupitdqpetdfum arc requirsd forthe ESRunit md for replumbing to install the unit. Thenuedsoopentionmd"cscosQ. A n E S R u n i t f o r r d proassor a n cost under $700. ~ecycler isss werage $125. is available from the silver, usurlly based on a par troy ounce ."t and the market price for silver (cumntly around $70 per troy ounce). Carr savings reducing the fixer replenishment rate by 6090%.
~ i b b 1 ~ from
Product Quality: None.
Employee Safety: Can reduce bath cbrngeouts md worker handling .nd exposure to waste fixer solution if recirculating system is employed.
RegulrrtolT Rcclrdrsnarts : If - dischqp change& permits m y be rsquirsd depalding on volume of solution trated. R e c i " * gunitsloatodwithinthe p C i M t U X ~ y n o t b e d M ~ u n i t s d , t h e n f o r e , ~ subject to trsrtmmt unit permit ie@"lt6. silver lenmved fnnn m ESR is huudaus waste. Silwr collector will rsquirS 8u EPA ID number for pickup.
Rsduces the unount of silver rad waste aolution in fixer bath effluent w h i c h m p y ~ w 8 t e r q u r l i t y . L4nvexsi lverco" 'oris in fixer bail reduces dver c4nlcentntion i n d brth becousc of reduced CUryOut from fixer bnth.
Releesestoot&rMedi.: None. Envimnmental W i t s
9
-tical Pollution Prevention Techniques for Lithographic PriDtSn
Effcts:
10
plrctid Pollution Prevention Techniques for Lithographic Printem
Image pro#uiry
E;npecttdw-- n: R u b t i d e W m of air e" d loss of product. Description: Both repl* d other 8olutiOnstb.tM keptnspr or cxmmced to the
should always be d e d or d to kbap volatile ampments of the chbaicrls in solution. plorting lids, ups, or other devices a n be used.
Feasibility:
Technical: Covers d lids must dow hookup to the photo pmxssor as "y. Developers have a volatile cozltmt of 6585%. Fixers are 4045% volatile.
Economic: Capiror apenditum are required for covers md lids. Special tanks and umtainers cmbeplI&Med frwrmurufjlcturers f6rsu,tosuo. ThetrnLsmdcontpiners have lids (floating or otherwiw), dust covels, d dkpmMer tubes. Wotoproaesor ClKdcal co8ts M r e d d by I lhhhiug prodact lors from snporrrtion.
Effects:
ProductQuality: None.
Employee Safety: Nonc. Regulatory Requimneak No permits required. ReleasestoothrMedi.: Nonc. Environmental Benetits: Reduces the need for virgin photopming chemicals and minimizes
air emissions narerrrted from chemical evaooration.
11
Practical Pollution Prevention Technique8 for Lithographic Printen
Expecteawa- : awtnmbathcuryoutbyuptotwp-thudr mdbathfep1- t
Description: ~~ following8llprocsrrinO solutionsmdwdles inuuomrtic pmmsiug l". squssoeer s i g n i f i d y d u c e the uIy)\mt of solution carried
r s d u c c s b a t h ~ ~ m d * l ~ t ntss beuum the bath solutionscm not
out of a bath on the film. "'bey mry also impraw silver recovery from the fixer bath because they serve to retnin the silver-bearing solution in this bath. This measure
&ai Out. mld the baths M not - by solutions from another bath.
Fersibility:
Technicrl:
Economic:
Squeegee rollem or bl.dsr or air qwogeea M mdabbb. Sqwegee rollers are the moldcommw. V e r y O f f i ~ ~ C r p ~ d ~ ~ f r o m t h e f i l m
sqlleem, carryover is C o d y 10 ml/ Eq. ft. silvcr arried over from fixer solution to th6 wash bath a n lead to wu" diaeh.+ps violations. Acwfding to
equipped with sqlleegces.
sprfics (some b dll rborbed by tho annltnion, "td .t 4.5-5.0 d ~ q . fi.). Without wiping action, c o ~ l l l ~ ~ ~ carryover is 15 d/q. ft. of m, with inefficimt
KodrL Company litemme, rackd-tank. brsket, ordrumproca" catmot be
Gapital from r e d d raw materid needs. With very efficieat oqueepese. .ppioximptely 3.3 ml of solutionis wed (from CIuIyOut) for srch square foot of film proctssed. This reduca the bath replhghmcnt rate by 50-9096 and saves on the cost of purchasing developer mld fixer ($40-50/five galloas). If tho solution is her, 19.8 mg of silver (0.6% of a troy ounce) is contained in the solution curyout, assuming a silver concentration of 6.0 mg/ml. Silver in the curyout cannot be rscovered since the washwater is typically not treated by aa electrolytic silver rscovery unit (See
is mquired for aqwegee btdhtion. Can savings M rrplinA
Technique No. 2). Effects:
Product Quality: Potential for physical damage to the photographic "id from the squeg-. This woutd not a f k t the printed product, but it would film rgocssing. Airsqusesessdonotrcntchthefilm.
Employees.fety: None. Regdatory Requkenent!~ No permits mquired. RaesscstoothaMcdi.: None. EnrirOmnenbl Bendits: Would reduce efflueat dischvge and the need for photographic
chemicals becauaeborhswouldnotbecomb contambted or drawn down as quickly. Would reduce silver concatration in washwater.
12
Practical Pollution Prevention Techniques for Lithographic Rintars
I- "ssiry
Technical: Replumbing of the d w a t a r bath system would be required to d the rscl.lllrrtioa unit.
Economic: Cat vuies by shop. Cupid apcnditun is q u i d for the rscircul.ti 011 unit (minimum of $500) and replumbing, and ongoing costs for opention and maintenance. Can savings are associated with decrepsed fresh water use, r e d d
and eacrgy savings. Effects:
Product Quality: None if the unit is opated properly d 'clan' wash" is available for film processing.
Emblovce Safetv: None.
13
I
Practical Pollution Prevention Techniques hr Lithogmphic Rinters
I-# plloasdnd
Technicrl: AutOmrtic come equipped with rbndby options. It m y be possible to retrofit older units which may not hrve standby Options. Man- should be c€mtacted.
EmployeeWety: Nom. -- : No permit8 mquirsd. R d ~ t o O t k M e d i . : Nom. EmirOrnnd Barbrc: Red- use md u)8oci.ted twl- barefits (e.&,
14
Practical Pollution Prevention Techniques for Litboorpphic Printem
Irnryc "ssinb
Expected Waste Reduction: Substantial reduction i n u " W e r due to dscrsurs in fresh water use. M p t i O n : kmS 8Ut0mrtiC provide 8 d l W U 8 flw Of fresh water 8ClWS the
film. o t h s r s r e q u i r e c o n t i n u o u s n p l ~ t of the wash bath when film is processed. With t h o types of opaations, the water is t y p i d y turned on in the morning md turned off in the ev&g unless the processor is equipped with an wtormtic wash bath or water control unit. Acoatrol unit if basically an dsctronic valve that only tume 011 whm film is being procssesd. Wd-mwnted control assemblies arc available to control the flow md of water to the wash
Te~hnicol: Wd-mounted control units CM k ktd led With my photoprocessor eqUipmt. A typical proceseor uses 1.3-2.6 gallons of washwater per minute. If the wash water is dowed to run for m 8-hwr period, 624-1248 o.llolu, of water would be required. If numingwrta is needed for only 10% of m &hwrpSriod, a control unit could reduce water u " p t i o n by 562 to 1,124 gallons.
Product Quality: A water control unit, if needed, would ensure product quality since it would p i & fresh water whea needed.
EmployeeSafcty: None. Regulatory Requkments: No petmits requirsd. ReleasestootherMeCti.: None.
15
proctiul Pollution Prevention Techaiq~m for Lithographic Printem
2.2 Pollution Prevention Techniques in pslztmroking
Pollution prevention techniques in pbemuking are limited far most printers. This is largely Itisunusualto because most lithographic printers have updated their platemahn 'gprocesJes.
find a printer still using metal etching in the platrmahn * g process. Printers primarily use prtsensitizcd plates and automatic platemalnn g CqUipmalL Given this situation, the only readily available pollution prevention technique in platemalan gisaqucousplatemahn . g, which is already
employed by a number of printers. In fact, based on a survey of a number of printers located in San Francisco, California, over half of the small printers (small pMtm make up 85% of the
printers in the San Frank) and all of the larger printers responded that they use aqueous platemaking. Aqueous platemaking is discussed in Technique No. 9.
16
Technical:
Economic:
prsstnsitized plates .ad aqueous develop^ must be from the “e mnnuf.cturer.
.ccommudate 4ueow chemicals d p”s. A q ~ e ~ u s proaap chemicals must be
solmt-b.ssd chemicals. Chemical chmgoout must be performsd mors often (e+, after every 200 p k nthcr than after 250 p b ) than with a traditional (solvent- based) proass. Therefore, chemical u8c is higher.
Older p l a t e ” - g equipment OrigiMIly deaipabd to UBb solvent-b.ssd developers can
veiy c l ~ r n to mrint.in p b qurlity. A~UCOUS c h d c a l life is 15-20% shorter thrn
Cqital apaditum is requid for m .queous pl.temrker ($5,000-15,000), unlsas an existing pl.tcmrlrtr is wed. Aquomu chemic& average $115 for 5 gallons. Solveat- based chemicals cost 10% less, although many ut no longer ~uf.ctursd. Cost savings ut rulized because d q o d of plate developing chemicals as bPEordous wpste (older solveat-brasd devalopers mry require hazardous WISte dispospl at a minimum of $3.60 per gallon) is no longer nccemuy.
Effeds:
Product Quality: None. Plate quality is at las t as good as that achieved with traditional plotemnlrsrs.
Employee S&ty:
Regulatory R4uin=- : No permits required.
Rdepscp to otha Medi.: All proass -ut wahnrdousandare discharged tothe sawer. Tdtionrl p” (imlmt-lmd) m y g”te hrprdous wastes
The eliminrtion of hazardous mrterids used in the platemaking process duces employee exposure to toxic chemicals.
d o r l l p r y be res t l id fromdischuge tothe WWCT.
their dischuge to the (Idwct.
the peacrrsiorr of hrnrdous wastes and the coaccms over En~~e!nta lBeaef i t s : l3huuks . .
17
Practical Pollution Prevention Techniqwr for Lithographic Printen
2.3 Pollution Prevention Techniques in Priniing
Practical Pollution Prevention Techniqwr for Lithographic Printen
2.3 Pollution Prevention Techniques in Priniing
Pollution prevention technique in the prinfing stage address material inputs, process modifications, equipment changes, and waste managemerrt practices. Printing provides many pollution prevention opportunities. Most do not nquk capital expenditures. Like the image
processing stage, cost savings arc realized from decrmsed labor requirements, material purchases, and hazardous waste disposat. A major benefit of the technique that focus on ink and solvent substitutions is a reduction in shop and ambient air quality impacts associated with
lower volatile organic compound (VOC) emissions. Printers have experienced some difficulties
with switching to low VOC washes and cleaners. In response, some vendors provide onsite
msultations to assist printers in making the switch.
Pollution Prevention Techniques Nos. 10-19, which arc listed below, present measures for
printing.
L
10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
18
I
Practical Pollution Prevention Techniques for Lithographic prinasn
-g
~~
Expectea Waste Reduction: Mini"wastep.psr aud ink f iombd ptbg nms .nd seduce VOC emissions. Dcperiptiool: This technique "ias the efficieacy of bqnopyl d&l (PA) d non-IPA
cuntaining fmtain solutions by maintaining tbmn at their optimum opcrahg tsmpennrra through refriguatiaa. For fountain solutim tht contain P A , nfrigeration CUI reduce VOC emissions md evaporative lossts. ?'ri#m' Wce mrnuficauss refrigention units.
FM*bility:
Tdlflicp1:
Economic: capital apcndirum am rsguind for tlm rehigemtion unit (S-gdon unit is $2,400) and ursoci.ted plumbing (S1,OOO). The b f i t s of refripmion (ducal fountain solution losses, waste paper d ink, better employee srfety) fu outweigh its cats. With non4PA solutions, cast suvings am r e d i d h m the reduction in evaporative IosSeS.
Effeds:
Product Quality: None.
Employee Safety: Regulatory Requirements: No pennits required.
CM improve shop air quality if IPA solutions are used.
Environmental BadiQ: Reduced waste pnse xuns P A fountain solutions reduces VOC emissions significantly.
reduced paper pnd ink waste. Using
19
Practical Pollution Prevention Techniques for Lithoorrphic printbn
-g
20
Practical Pollution Prevention Techniques for Lithorppphic printerr
-g
Economic:
EffedS:
Capad apedjswcj are requirsd for inst.lling ink levelers. cart savings wil l be mli7lul from reduced lossof paper and ink inbd pmsn n m s d waste ink disposal.
Product Quality: None.
Employee Safety: Naac. R e g d a t o r y ~ e n t s Nopermitsrequird. RdeascstoothaMcdi.: None. Enrironmental BencTrb: Reduces ink uae d .(L8oci.tdd waste ink disposrl, and reducts the
21
Practical Pollution Prevention Techniques for Li&ographic Printem
Employee Safety:
Regulatory Requiranents: No permits requirsd. May help to meet VOC emission limitations for
Help to improve the indoor air @ty )rmurs VOC cmisaions arc significantly feduced or eliminrted depsadig on the product.
swlb printers.
ReleasestoOthcrMedia: None. Enriromnental Bcndits: Contributes to shop rod r e g i d air quality improvenuats by
aluntarrtinn of s i n n i f i d y reducing VOC emissions. . .
22
Practical Pollution Prevention Techniques for Lithographic Printen
-8
Technical: This measure is highly feasible. Pintera muet "b the umunt of residual liquid intherap. A r a g m l l c c t i ~ d n u n S h o u l d b e ~ m d ~ . t t h e b o t r o m t o keep the rap from contacting the liquids that have drrrined. Rags may be ceatrifused to "eve excess liquih. Rags sbouldnotbeused forclsrninp up spills. Citrus- based cleaners, if &, react with other liquids in a rag collection dxum.
Economic:
Effocts:
Using a laundry b c e for rag supply is significantly less expeawive than purchasing new rags. No capital aprndiure is rsquixed.
ProductQuaIity: None.
Employee Safety: None. Regulatory Requhuua~e No permits rsquiisd onsite. Must meet the acceptance reqUinmen ts
of the lnunQv service.
Releases to othr Mcdir: W " m t e r is gemntcd (ofhite) fromlurndenn * gtherags. Extviro~ental W i t s : Provides for the reuse of a matwid that would otbsrwisc be a solid
waste. virtu ally^ the need for purchasing new rags at the &on level.
24
Practical Pollution Prevention Technique6 for Lithographic Rh"
Technical: Pmsss must have sufficitnt cleurnce under the blanket rollers to & automatic washes. Press maauk- should h o w if such can be installed. Smaller presses may not Iuve d c k t c l"ce .
ProductQuality: None.
Employee Sofkty: Regulatory Requiranarts: No permits requid. ReIea~stoothcrMedia: None. Environmental &nelts:
Reduccs solvent huuilinp and IsBoci.tdd employee exposure to toxic chemicals.
May reduce oolvcat urs, m"l waste solvmt geaention, and voc emi&3ions.
25
I -
Practical pollution Prevention Techniques for Lithographic Printers
-g
Economic: Printers have to consider the cost of additional labor time aad press downtime
Low VOC solvenb are slightly more expensive per gallon (SZ-S/gd. more) than traditional pnss washes. No capital aqnnditun is required.
(Wniting for the solveat to dry) g m d l y 8smxhtd with using low voc solvents.
ProductQdity: None.
Employee Safety:
RcgulatorJrRcq : No permits required. Releases to Other Media: Becruae larger qumtitiea of solveats mny be needed, more waste
solvent is gumated.
Envi"enCp1 Bendits: Reduced VOC emissions imwoveS indoor and m m d air aunlihr.
Impmwd indoor air @ty with rsduced VOC emissions. Howavcr, workem IImy be axpossd to larger qumtitiw of solveats.
*
26
Practical Pollution Prevention Techniques for Lithooraphic Printers
Expcrtcaww- Signifhat reduction in rolvsnt wmb gumatha
Dcscriptioa: wub s o l V ~ M gl”td fromprerr clearup. wub solvcpteub luzadcm u ” ~ d must be mrrugedpmpdy, m w t o f h b y dispoaltbroughincinerrtionor eaeqy mcovy (e+, by -t kilns). ’Ihir measure involves recycling waste solvmts through a licsased ofbite solvmt recycler. Solveat recyclers clean, mgalera&, d #ell used solvmts as rccycld eolvmt pmducts. Recycled solvtnts
be U d for lnMy purpoasr. Feasibility:
Tschnicrl: Printersmustsegreg8t8usuioolveatfromother~ wastes, suchas wistc ink and fountain solution. m it a u be collected for recycling. Recyclers may not pick up solveats if they M * WithotlIarwrStsr.
Economic: Effects:
No additional cats for solvtnt mycling. No @tal upenditam is requid.
ProductQuahty: None.
Employee Safety: None. Regulatory Requimuasts: No permits rapired onsite. Ihe solvent recycler must be a lianssd
hauler. RelessestoothrMedk None. Environmental &ne2ib: Recycling solveat rsduces the uIy)\mt of hsnrdourr wastes inchrated
emissioas. purchrwn g recycled solvents duces the need for virgin solvmt products and promotes a healthy solvcat recycling industry.
orburabdforeaergy. ~ t r s l t m s a t m e t h o d s ~ 8 i r
27
Pmctical Pollution Prevention Tachniquea for Lithographic printsrr
plincinl
~ w 8 s t e R c d u d i o a : R s d p o s r ~ r o l v a a t ~ g a m t i a Q . Dgcriptioa: As put of the piarr c k b g p", prinQnuaea " w d a k t o c l e r n d pub
thatcm be removed -the piarr mdplrcsd in the rolvcatsink. A solveat sink is literally a s t d sink (she de) that pats a n be plreed in md clsared with solveat.
amy be recycled through a filter system in the sink (used film may be hPPvdous waste), or it may be used until it is dirty a d no longex effactivb at wbich tinw it is removed by a lltrvicb c0mp.n~. Somice Compmiss, sucb as Safety Kleco, supply the equipment a d service these sinks 011 1 regular basis. Such sinks typically use
use 1 filtration system which significantly exteads the life of the solveat arc available for purchase. Zep M-g Company mrksr thezCpDynu Reclaim System, md Recvm Applied solutiont, I n a q w m t d , mrlrsr the &&e Tak P a m Washer System
'Ibe solveat is supplied froma barrel baaw the dakmd is "Wed . Tbssolveat
recycled solveat which the d c e C 0 " y suppliacl md recycles Puts waEhOr8 tht
whichcmbepudasod.
Technical: Solveat Sinio am only a p p q m a b ' forusoifpartsanbe.a*iynmovsdadtakento the sink for c ! ~ . Feasibility will vary dspepdino on the type of prsss.
ProductQuality: None.
Employec Safety: Regulatory Requirancnb: No permits required onsite. The solvent sink supplier must be a
l i d supplier a d solveat recycler. 'I" printer must have an EPA ID number if a solvent sink service is used.
Reduces the use of virgin sow md dirpocnl of waste solveat.
Improved worker srfcty because of reduced handling of solvent-laden rags.
ReleasestoOtherMedt: Nom. Enriromncntpl Bcnbb:
28
Practical Pollution Prevention Techniques for Lithographic Printen
APPENDIX A
SUMMARY OF LITHOGRAPHIC PRINTING PROCESSES
Practical Pollution Prevention Techniques fw Lithographic printerr
APPENDIX A SUMMARY OF LITEOGRAPHIC PRINTING PROCESSES
This appendix contains detailed information on the three processes of lithographic printing, the wastes associated with each process, and common waste management practices employed by this
industry.
Photoprocessln ' g for printing does not Mer from p h o t o p " ' g for any other use. Photo
negatives are typically developed by immersing them sequentially in processing chemicals including developers, fixers, stabilizers, activators, and others. The use of a particular
processing chemical depends on the type and amount of developing needed. Processing solutions
contain a number of hazardous chemicals that can be discharged to the sewer or must be handled
as hazardous wastes, depending on the discharge requirements of the publicly owned treatment
works (POTW). Spent fixer solutions usually contain Varying concentrations of silver which is
washed from the film negatives. Many printers are required to remove silver from their waste
streams to meet sewer discharge permit requirements imposed under P O W pretreatment
programs. For example, in San Francisco, silver concentrations are not allowed to exceed 0.3 parts per million (ppm). Because of these requirements, many printers have silver recovery units onsite. For onsite silver recovery, the State of California "permit by rule" program for
hazardous waste generators allows printers to install these units without obtaining a hazardous
waste permit for treatment if the amount treated is under a threshold value (500 gallons).
Printers must stil l notify the state or local agency. Other printers have their spent fixer hauled
offsite by a licensed hazardous waste hauler and recycled or treated offsite. Printers must have
an EPA 1.1). number to have this waste hauled offsite. Film negatives and other photographic
papers that are generated from photoprocasing are considered nonhazardous solid wastes and are often recycled for their silver content.
A- 1
Practical Pollution Prevention Techniques for Lith-hk Printem
The platemaking process uses developed film and various procesSing solutions to imprint the film
image onto the plate. Plates are typically metal (mostly aluminum), but can also be plastic or paper. Plastic and paper plates are designed for small printing presses and shorter runs, that is,
a limited number of each piece. Processing solutions, depending on the type of platemaking
equipment, may be entirely nonhazardous aqueous solutions, or they may be of a chemical
makeup similar to photographic procesSing developers and fixers, or emulsification solutions. Waste processing solutions and used plates are generated in the platemaking stage. Used printing plates are considered a nonhazardous solid waste. Waste procesSing solutions are
discharged to the sewer, if aqueous based, and the plates arc recycled, if aluminum. Waste
procesSing solutions that axe solvent based arc handled as hazardous wastes.
Printing refers to the operations that occuf on and around a printing press. This process varies
significantly between small and large printers. For instance, small printers usually have small sheet-fed presses; larger printers may have multiple presses ranging b m large sheet-fed to web
presses. In this process, the developed plate is run through the press. The image on the plate is transfend to a blanket cylinder through a combination of ink and fountain solution and offset
to another surface, such as paper. The fountain solution displaces the ink in places where the
plate has no image. Some presses also have a built-in finishing process to add a glossy surface. Printing generates waste ink and fountain solution. Typically, the printed surfaces selfdry after
running through the press. However, large web presses usually require oven drying. Due to the large generation of volatile organic compounds (VOC) associated with oven drying, these
presses are often required to have thermal oxidizers or catalytic converters to destroy the VOCs.
For example, in the San Francisco Bay Area, afterburners must be installed to destroy 90 brcent of the VOCS.
A-2
I
Practical Pollution Prevention Techniques for Lithoglrphic Printerr
There are scveral types of inks and fountain solutions. The types of inks include petroleum oil based, soybean oil based, rubber, and water based. The use of these inks typically varies
between printers and printing needs. These needs depend on the printed surface and the
ap~earan~e desired. Currently, printcrS tesld to- soybean 0 i l - W inks Which reduce VOC generation.
Fountain solutions have been greatly improved. Recently, many print.cn phased out the use of isopropyl alcohol as a fountain solution and are using low VOC or nontoxic substitutes. Now
most major printing suppliers market aqueous-based fountain solutions. In the past, isopropyl
alcohol was the standard for fountain solutions because it provided predictable and consistent
behavior on press. This phaseout was initiated primarily by the emerging air pollution control
requirements. Some small printers, however, are still using isopropyl alcohol. To maintain
concentration, many printers with large presses refrigerate their fountain solutions. This
technique reduces product evaporation and loss and maintains solution consistency.
Waste inks are generated as a result of process losses during normal operations, inks left over
and removed from the press, and unused supplies of ink that may have an e x p a shelf life.
Printers control their ink inventories to avoid accumulating unusable inks. The waste inks that
are generated must be disposed of as a hazardous waste. If possible, the inks are donated to schools or mixed with black to create a "house" color. Inks are considered a hazardous waste
due to their metal pigment content. Some ink colors are much more toxic than others. Colors
such as red, purple, and yellow are the most toxic because they contain inorganic metallic pigments such as cadmium or chromium.
Smaller printers generate small amounts of waste ink from the press. They typically collect drips of waste ink or wipe off unused portions of ink with paper and subsequently dispose of it
as a solid waste, after the ink is dry. The larger printers usually drum up the waste inks and
have them hauled off for incineration and energy recovery.
A-3
prsCtical Pollution Prevention Techniques for Lithographic Printen
presses are typically cleaned at the end of the day or between jobs. Cleaning needs differ among press types. Rags, blanket washes, and solvents are commonly used to m u a l l y clean
press rollers as well as ink trays and tools. Larger presscs may have automatic blanket washes
on the presses to red- labor requhment~. A l t h ~ ~ g h mlvent-based products are typically used for cleaning, nduced VOC solvents or less toxic altcmativcs, like citrus-based cleaners, are increasingly being experimented with. Waste solvents are drummed and commonly picked up
by a waste hauler for offsite treatment (usually hcineration). Some Cities, such as San Francisco, run very small quantity generator (VSQG) pgrams to assist VSQGs in cost-
effectively disposing of their waste. The rags used to clean parts manually are t y p i d y laundered offsite.
Practical Poliution Prevention Techniquefa for Lithogrrphic Printers
APPENDIX B TECHNICAL, ECONOMIC, AND ENvIR0"TAL
CHARACTERTSTICS OF PRODUCTS COMMONLY USED IN THE LITHOGRAPHIC PRINTING INDUSTRY
The information presented in this appendix is intended to provide printem with some
information on products that are readily available and are commonly used in the printing
industry. Many of the products described support information provided in Section 3,
Pollution Prevention Techniques. This appendix provides actual product names for
products and equipment. Although many of the major products used in the lithographic
printing industry are listed in this appendix, it does not reprant a comprehensive product
inventory. Product data information including prices are from the fall and winter of
1993/1994.
Inclusion of a product in this appendix does not constitute an endorsement or support in any manner.
Practical Pollution Prevention Techaiqwr for Lithographic Printe~
APPENDIX B TECHNICAL, ECONOMIC, AND ENVIRONMENTAL CHARACTE3RIsTICS OF PRODUCTS
COMMONLY USED IN TEE LITEOGRAPHIC PRINTING INDUSTRY
PHOTOPROCESSING
Developer Kodak Ultratech $4315 gals 3enefit4: compatible with slightly toxic;
automatic PrOCOSSOM noncarcinogenic
-:unknown . . .
DuPont Contact supplier &ne-: compatible with all Slightly to moderately DUCARE@" Recycled Developer
"Quanta-onC' Developer Replenisher
3M Excellerate
automatic procerron
-: contains oxidation productr that virgin developcn do not which may .flFect product quality
. . .
M: recycled product compatible with all ~~OCOUOM
toxic; noncrucinogenic
n415 gals Bnefitq: compatible with all automatic ~~OCNSOM
1 slightly toxic; noncarcinogenic
Notes: 1. Toxicitv Ratinn or Class
Practically nontoxic slightly toxic Moderately toxic Very toxic Extremely toxic supertoxic
<5 mgACg 5-50 mglKg
20-500 mgKg 0.54 gACg 5-15 gncg >15 n/KP
If discharged to mwer, waste developer may enter and degrade receiving waters. Waste developer may contain silver pprticles.
If discharged to sewer, waste developor may enter and degrade receiving -M. Waste developer may contain silver particles. Hydroquinone, a component of the 'Quant.a-0" developer replenisher, is extremely toxic to aquatic life.
If discharged to sewer, waste developer may enter and degrade receiving waters. Waste developer may contain silver particles.
El
Practical Pollution Prevention Techniqwr for Lithogtaphic Printers
APPENDIX B TECHNICAL, ECONOMIC, AND E"MENTAL CHARACTERISTICS OF PRODUCTS
COMMONLY USED IN THE LITEOGRAPHIC PRINTING INDUSTRY (continued)
PHOTOPROCESSING
KodakUltratech
DuPont DUCAREe Recycled Fixer
DuPont Liquid Fixer .Part A -Part B
1M Excellerate
Contact supplier
Contact supplier
~
$5515 gals
Film Yerox Verdeprint Contact supplier
m: compatible with all automatic procerwwr
UQ: recycled product b compatible with all automatic Pm-
mitations: unknown
kwfiq: compatible with all automatic processors
uitatiopi: unlawrwn
Benefitp: compatible with all automatic procamor8
-:unknown
Beoefitr: process occur8 in dry snvironrnent. No waste silver; quality comparable to aqueous processes
-: new technology
slightly toxic; noncarcinogenic
Moderately toxic; noncarcinogenic
PIut A, slightly to moderately toxic. Part B, very toxic; noncucinogenic
slightly toxic; Mnrcprcinogenic
If sewed, waste fixer may enter and degrade receiving waters. Waste fixer can contain silver particles from silver halide filmr. Contents are moderately toxic to aquatic life.
If aewered, wpdb h e r may enter and degrade receiving waters. Waste fixer can contain silver particles from silver halide films. Components are moderately toxic to very toxic to aquatic life.
If wwered, waste fixer may enter and degrade receiving waters. Waste fixer can contain silver particles from silver halide h. part B- components are moderately toxic to very toxic to aquatic life.
If wwered, waste fixer may enter and degrade receiving waters. Waue fixer can contain silver particles from aver balide films.
UnlcMnvn.
E 2
Practical PoIlution Prevention Techniques for Lithopphic Printers
APPENDIX B TECHNICAL, ECONOMIC, AND ENVIRONMENTAL CHARAC’lZRISTICS OF PRODUCTS
COMMONLY USED IN TEE rSraOGRAPHIC PRINTING INDUSTRY (continued)
PLATEMAKING
Plate Developing I
3M V i g Developer I $1195 gals
DuPont AQ Machine kveloper Top Up
3nco Aqua-Dev leveloper
Codalr Aqua-Image kveloper
E1 195 gals
E 1 15/5 gals
P6/5 gals for lolutions
I Benefip: yields high quality PI- . . . -:increaeefin
chpaoeout -Y comppred to solvent-based developers; bath solution must be kept very clean
slightly toxic; noncarcinogenic
M: yields high quality P h
utatioph: increane in changeout frequency compared to rolvent-bad develapen; bath rolution must be kept very clean
slightly toxic; noncucinopenic
bnefie: yields high quality plates
mitatiom: increase in changeout frequency compared to solvent-based developers; bath solution must be kept very clean
I
slightly toxic; nonccucinogenic
bnefitq: yields high quality P b S
slightly toxic; noocrucinogenic
Li&atioll& increane in changeout frequency compared to solvent-based developers; bath solution must be kept very clean 1
Waste processing solutions discharged to a wastewater treatment system do not pose a hazard.
waste processing rolutions
treatment syu” do not pose discharged to a wumvater
a hazard.
waste processing rolutions discharged to a wastewater treatment rystem do not pose a hazard.
waste processing solution8 discharged to a wastewater treatment ryrtem do not pose ahazard.
E 3
Practical Pollution Prevention Techniques for Lithogr8phic Printem
APPENDIX B TECHNICAL, ECONOMIC, AND ENVIRONMENTAL CHARACTERISTICS OF PRODUCTS
COMMONLY USED IN TEE LITHOGRAPHIC PRINTING INDUSTRY (continued)
PLATEMAKING h e r technologies (various manufkcturers)
Plat- . _- Presenaitized Aluminum p h m ('Em Printing Products, 3M, DuPont, Kodak)
Paper plates (several ,rands)
Plastic (onyx) plates :several brands)
-: have not been developed to meet the high quality s"h tor
I h t b m h k D- I - * 1
Average $15-18 for 40 inch plats
~~~
Contact supplier
Contact supplier
J6glitations: must be p " d with same brand dovelaper
Benefits:cortslcgthpn aluminum plates
-: ailver not recoverable onaite
wtatio44: designed for limited number of printed pieces (l0,ooO)
I
Now
None
NOW
waste platesare nonhazardous mlid waste.
Waste plates are non- recyclable, nonhazardous solid waste.
Waste plates are non- recyclable, nonhazardous mlid waste.
B-4
Practical Pollution Prevention Technique6 for Lithographic Printers
APPENDIX B TECHNICAL, ECONOMIC, AND E"MENTAc CHARACTERISTICS OF PRODUCTS
COMMONLY USED IN THE LITHOGRAPHIC PRINTING INDUSTRY (continued)
PRINTING
Kohl L Madden ultrasoy 11
Gans 'Enviroset Process Inks (soy- based ink)
Gans Drisoy, Dri-Print (soy-based)
Black: S7lunit Blue: S8lunit Rcd: S8lunit Yellow:
fintficg: fast retting; contain8
-:unknown
no petroleum hydrocarbons
. . .
Black $8/unit cyan: SWunit Magenta: sulunit Yellow: sulunit
Black: SlOlunit cyan: s35lunit Magenta: $35/unit Yellow: S35lunit
Benefits: fast setting
bmlEptronr: untarawn . . .
Black E81unit cyan: W u n i t Magentp: W u n i t Yellaw: W u n i t
Benefits: fast retting
Liplitations: unknown
slightly toxic; noncarcinogenic
slightly toxic; POttntirrllY carcinogenic
sli$htly toxic; carcinogenicity Unlcnown
Moderately toxic; carcinogenicity UnLnorm
Low VOC emissions (product is 0% petroleum hydrocarbons).
VOC emissions (product is 16% petroleum hydrocarbons).
Hnzardous decomposition product.
VOC emitsions (product is 30% petroleum hydrocarbons).
Hazardous decomposition product.
VOC emissions (product is 27% petroleum hydrocarbons).
Hnzardour decomposition product.
Notes: 2. Inkunit = 1 pound
B-5
Practical Pollution Prevention Techniques for Lithographic Printem
APPElNDIx B " I C A L , ECONOMIC, AND ENVIRONMENTAL CaARAcTERIsTICS OF PRODUCTS
COMMONLY USED IN THE LITHOGRAPHIC INDUSTRY (continued)
PRINTING Ganr Soytech Web Forms Ink (roy-bd)
Fed Ink (SOY--)
Wesum Ink Soya R II inks
Black: $7/unit min. 5 unit8 Cp: $7lunit min. 5 unit8 Magenta: SNUnit min. 5 units Yellow: ntunit min. 5 unit8
Blrrck: Slunit Cyall: S22lunit Magenta: S22lunit Yellow: S22/unit
Contact supplier
Contact supplier
Gans DrisOy Gloss, Drisoy spot, Drisoy
Sslunit
mfitg: contains 00 petroleum hydrocarbons; stable and c lan runniao
Lip3itatioqg dry8 slower than petroleum-bamd inb product
metallic and fluom"t roy inks not currently available
bnefie: contains 00 petroleum hydrocarbons; glorry; rub
quality may be affww
WitatioM: dryr dower than petroleum-ba#d *, product quality may be imp.cted
Benefits: fast setring
btatiopa: unknown
BppefiQ: fast setting
bmitations: generates mbdantial VOC emissions
wtatiopk: unknown
slightly toxic; CrvcinOnCniCitv
slightly toxic; carcinogenicity unknown
UnknOWXl
Toxicity unknown
slightly toxic; n o ~ i n o g e n i c
Law VOC emissions (product is 0% petroleum hydrocarbons).
HPzardous decomposition product.
h VOC CmiSSiOM (product is 0% petroleum hydrocart").
Hazprdour decomposition product.
VOC emissions (product is 1- 20% petroleum hydrocarbons).
VOC emissions (product is 40% petroleum hydrocarbons).
voc emissim (product is 17% petroleum hydmcarbons).
Hnzadou decomposition prOduct8.
B-6
Practical Pollution Prevention Techniques for Lithographic Printen
m: mirror glua finirh
fimitations: unknown
APPENDIX B TECHNICAL, ECONOMIC, AND ElVVIR0"TA.L CHARACTERISTICS OF PRODUCTS
COMMONLY USED IN THE LITHoGRApBnC PRINTING INDUSTRY (continued)
slightly toxic; noncarcinogenic
PRINTING Gans Marlite S8lunit I Fountain Solutions Isopropyl aicohol (Shell)
Silverline Photo Meg Plate Etch
Suranol - Summit Fountain Solution
Prisco Alkalw R
s17/gal
$21/gal price based on 55 gal
Contact supplier
M: quick drying; consistent behavior on prsrr
-: g e n e " hunrdour~drpbrtsnti. l voc emissions
. . .
~ ~ ~ _ _ _ _ ~
Benefio: quick drying; "sirtent behavior on press
Benefits:aqueousbased;nota ha"6 material, chemical, or substance for handling PUrpores
Liplitatioaq: glycol in product can glaze rollers; smaller operating range than P A huntpin mlutiom
Bnefi~: e l i " alcohol and glycol from fountain solution; no evaporation
I6pritatiow: smaller operating range than P A solutions
VOC emissions (product is 1842% petroleum hydrocarbons).
Hazardous decomposition products generated.
Moderately toxic; "carcinogenic
Moderately toxic; carcinogenic
Practically nontoxic;
testing has not bsen toxicity
p e r f O l m d
Practically nontoxic; PbncuCillOgOniC
voc is 100%.
Hazardous decomposition products generated.
VOC content is 30-35 96.
Hazardous decomposition products generated.
VOC content is 0%.
Low VOC emirrionr.
E7
Practical Pollution Prevention Techniques for Lithographic Printen
APPENDIX B TECHNICAL, ECONOMIC, AND ENVIRONMENTAL CHARACTERISTICS OF PRODUCTS
COMMONLY USED IN THE LITHOGRAPHIC F R X " G INDUSTRY (continued)
Prisco Q Seriea Fountain Solution Concentrate
Varn aqueous basad fountain solution
Prisco Enviroklene 1.6
Prisco Environmental wries I, 11, & IU
h m California Wash
Contact supplier
Contact supplier
Contact supplier
Zontact supplier
iU/gal bwd on 5 gal ~Urcham
Bswfitr: eliminlt.l. need for alcohol or alcohol subditutes; noncarcinogenic no evaporation
Liglitations: unknown
M: aqueuua W, not a hazardow rmtsrirrl, chemical, or substance for lundlhg PWO=
Practically nontoxic;
Practically nontoxic
-: glycol in product CUL glaze rollera; m d e r OpedngrrnqethrnIPA
I
will not CIUW web Noncarcinogenic brsrltr, almort no odor; rin#d with water
-: slower drying than higher VOC products
Bnefitg: systematic reduction Noncarcinogenic of VOCO
Limitations: slowcr drying than higher VOC products
Bellefit& aqueoull bpwd; can
-unknown
slightly toxic; beriruedwithmur noncarcinogenic
. . .
No VOC emirrions.
VOC content is 0%.
VOC content is 1.6 lbdgal.
~
VOC content in Step 4 is 1.0 Ibdgal.
VOC content is 6.6 lblgal.
Hpzprdourmrrterialand waste.
B-8
Practical Pollution Prevention Techniques for Lithographic Printers
APPENDIX B TEcfINICAL, ECONOMIC, AND E"MENTAL CHARAC"ERTSTICS OF PRODUCTS
COMMONLY USED IN TEE LITEIOGMPHIC P R I " G INDUSTRY (continued)
~~ ~
Varn Color Wash Step 1 & Step 2
Varn Ecolo Clean QD
Flint Ink R-41 Cleaner
Safety Kleen Parts Washer
S14lgd
s131gal 5gal S81gal 55 gal
WOfS gal SlOlgal b a d on 5 gal purchase
$2081 month for equipment rend & solvent service
$700 for 1 Dyna Clean System
Bewfitr: reducer cleanup time
-: Color WIuh Step 1 and 2 must be wed together
. . .
Ljylitatiosa: dower drying than higher VOC pdwu
bncfitp: redwea cleanup time
&nefiy: no solvenu are dirportd of (Safety Kleen assumes manifest responsibility); l e g solvent used because solvent is recycled
-: applicable only if parts can be removed from prerser for cleaning
BtDefits: filter and rscirculatiop system extends solvent life; replaceable filten; doea not ewpo-
-: applicable onIy if parts can be removed from ~resscs for cleaninn
Slightly to moderatel] toxic; noncarcinogenic
Slightly to moderatel] toxic; noncarcinogenic
Moderately toxic; noncarcinogenic
Unlcaowa
VOC content is 5-6.8 Iblgal.
Hazardous material and waste.
VOC content 3.5 Iblgal.
Hazardous material and waste.
VOC content is 100%.
€iazardousmaterialand waste.
VOC emissions.
Law VOC emissions.
B-9
APPENDIX G
ADDITIONAL REFERENCES
Abramic, Karen. Eco-Friendty Paper. American Printer, 213:l (1994), pp. 58-61.
herican Paper Institute, Inc. Amws to Optn-AsM Queshns About printing-Writing Papcrs and Recycling. Washington, D.C.: API Papex Information Center, 1994.
Blessing, Rose. "Recycled Paper: Upping the Ante." Mlishing & Pmduuion E " w 8:1 (1994), pp. 37-41.
Cross, Linda and Ynostraza, Roger. "Plate Technology Drives Waterless." Graphic Am Monthly (April 1993), pp. 59-63.
Cross, Linda and Ynostraza, Roger. "Watershed Yuus For W8tQless." G ~ p h i c Am Montw (F~~~wIY 1993), pp. 51-53.
Cross, Linda and Ynostraza, Roger. "Ink, T e m p e " Systems Advance Waterless." Graphic AHS Month& (April 1993), pp.53-57.
DeJidas, Lloyd P., Jr. "Alcohol Substitutes: Making Them Work For You." Gq#hwrZd 1:4 (1992), pp. 1-8.
DeJidas, Lloyd P. and -tree, Thomas M. "Dampening Solution Primer." @?world 2.5 '
(1990), pp. 1-7.
Dennis, Ervin A. and Jenkins, John D. Compensiw Graphic Am, 3rd ed. Lalce Forest: Macmillan/McGraw-Hill, 1991.
Donvito, Thomas N.; Turan, Thomas S.; and Wilson, James R. "Heavy Metal Analysis of Inks: A Survey. TAPPI Joumal 75 (1992), pp. 163-170.
Eldrad, Nelson R. (3tmistry for the Graphic Am. 2nd ed. Pittsburgh: Graphic Arts Technical Foundation, 1992.
Gavaskar, Arun R.; Olfenbuttel, Robert. F.; and Jones, Jody A. &-site W e Ink Recycling EPA 6o.SR-92-251. C h c h a t ~ *: Risk Reduction Engineering Laboratory, US Environmental Protection Agency, 1993.
Graphic Arb Technical Foundation. Operating the Inking @stem on the Sheqfied met Press #0651. Pittsburg, 1989.
G - 1 MARCH 1996
mLLUTION -ON APPENDIXG TRAmmC W"s9 GUIDE
Hanna, Jim. Hazardorcs Waste Reduction Hondbooik &nrnexial Print Shops. Reports for Government (October lm), pp. 9-13, 22-23.
Hannaford, Steve. "Digital proofins Gains Acceptance.' color Acblishing (May/June 1994), p ~ . 12-17.
Hartsuch, Paul J. C % " y f i r the Graphic Am. Pittsburgh: Graphic Arts Technical Foundation, 1983.
He", Keith. "The Softer Side of Pmofhg." Color Publishing (May/June 1994), pp. 45-46.
Huisingh, Donald; Martin, Larry; Hilga, Helene; and Seldman, Neil. Proven m,jCr;rfiom PoUwion Pmenn'orr Cart Wes in Resome Conservation and Wate Reducton. Washington D.C.: Institute for Local Sclf-Rcliance, 1986.
Hutchinson, Geoffrey H. "Developments in the Technology and Applications of Offset Lithographic printing Inks." Ckmistry and Indurny 22 (1980, pp. 764-769.
Indiana Department of Envinmmcntal Management. Pollwion Rvwnzion for Printing. Indianapolis: Office of Air Management and Office of Pollution Revention and Technical Assistance, 1993.
Institute for Local Self-Rtliance. Towwd Pollution-Fke M w m * n g : AMA Management Bnejing. Washington, D.C., 1986.
Iowa Waste Reduction Center. P o W o n A.n;rcntion Manual f i r Lithographic Printers. University of Northern Iowa, 1995.
Jacobs Engheerhg Group, Inc. Waste Audit Snrdy c0"Crc'al Printing Indrrmy. Sacramento: California Department of Toxic Substance Control, 1989.
KODAK. "Drsposal of Small Volumes of Photographic procesSn g Solutions." KODAK Buuuin J-52 (1986).
Lewis, A. F. Blue Bod M a g Ii@" Repom: m h i c Am Indrrnry Analysis by Plant Size, Equipmen, Rotkt S'es. New York: A. F. Lewis & Co., Inc., 1991.
Logsdon, Gene. "Canadian Company Solves Disposal Problem for Printers." BWWk 34:1 (1993), pp. 78-79.
Lustig, Theodore. "Do Ink Oils Evaporate?" Gmphic Am Monthly (May 1993), pp. 100-103.
G - 2 MARCH 1996
Mabbe€t&Assoclates * , Inc. Conno1 Techniques Guidelim (cn;S) for m a Lithography. New England Printer & Publisher (August 1993).
the Performance of Dampening Systems." . . MacPhee, John. "18 Tips On How to Gu@vorld 2.5 (1990), pp. 8-9.
Nahm, Steven H. "Prospects for Radiation Cured Coatings in Food Contact Applications." Joumal of W n g s Technology 63.789 (1991), pp. 47-53.
NAPL. Waterless Printing. Audio tape, 1993.
National Association of Printing Ink Manufacturers, Inc. A Reahtic Appraisal of Suy Inks. Hasbrouck Heights, 1991.
National Soy Ink I n f i x " Center. pnwnotablc C?m"ctristics of Soy Ink. West Des Moines, 1994.
of Air Quality PlaMing and Standards. Cbnnvl of Volatile Organic Compound Emissiorts from m e t Lithographic Prim'ng. Research Triangle Park, US Environmental Proteztion Agency, 1993.
Pferdehirt, Wayne P. "Case Study: Roll the Presses, but Hold the Wastes: €2 and the Printing Industry." Pollution Prcwm'on Review 2:4 (1993), pp. 437-456.
Pope, David. "Digital Presses: Beyond the Scenes and Beyond the Hype." Color Wlishing (Much/Apd 1994), p ~ . 15-22.
Printing Manager Staff. "Soy Ink: Just Full of Beans?" Printing Manager (July/August 1991).
Reid. "Prepressing Issues." Priming Impmsiom Guide to E W h " a l Compliance. (February 1993).
Research & Engincuing Council of the Graphic Arts Industry. "Managing Environmental Issues of the 1990's." &h Endmnmtnt4J Cbncemfor thc Priruer/Wlisher &minar. Chad& Ford, 1992.
Research & Engineering Council of the Graphic Arts Industry. "Understanding & Managing Environmental Issues Today & Tomorrow." 9rh Endmnmental Conanrr for the Printer/Publisher Seminar. Chadds Ford, 1993.
Romano, Frank. "The Digital Printshop, As Digital Technology Advances, Remember to Keep
G - 3 MARCH 1996
mUUTION -ON AnwDnsG T l u l M N c I " s ' GUIDE
An Eye on the Big Picture." Amenam tinter (February 1994), pp. 4042. I
I Rosinski, Jean. A Summary of the Envimnmental Inpact of Soy Ink Recycled l@hi?nZ Wate. - Frankenmuth: Printing Pilot Plant, Westan Michigan UniverSity, 1992.
Roth, Bill. "Digital Presses Make Short Run Profitable." t in t ing Manager (January/Febmry 1994).
Schneider, Robert J., Jr. qpCmti*ng the Dampening @stem on the S h e e l d Q@et h s . Pittsburgh: Graphic Arts Technical Foundation, Inc., 1990.
Tebeau, Cliff M. "Adhesive Recyclabfity Update." m e e d h g s of the 1992 Envhmnental Concenrsjibr the Printer Siminar. Chadds Ford: Research & Enginaaing Council of the Graphic Arts Industry, Inc., 1992.
Tebeau, Cliff M. "Recycling Printed Products." Rvceedhgs ofthe 1993 Envimnmental conctnrsjibr the tinter/Publisher Seminar. Chadds Ford: Research & Engineering Council of the Graphic Arts Industry, Inc., 1993.
Tellus Institute. Substitution W e Study: Altemativcs w Solvent and Petrvleum-Baed I d . Lowell: Toxics Use Reduction Institute, University of Massachusetts, 1993.
Ungurait, James and Wolfe, Norman. "Don't Gloss Over the Issues." Americun Ainter. (October 1991), pp. 40-42.
United States Environmental Protection Agency. lk Commercial Printing Indrrrtry. United Washington, D.C., 1990.
United States Environmental Protection Agency. Wmte Minimization Oppmnity hessment Munual EPA 652-7-88-093. Cincinnati: Hazardous Waste Enghming Rtscarch Laboratory, Office of Research & Development, 1988.
United States Environmental Protection Agency. Guides to PouUrion hveruioir Thc Commercirzl Aiming Industry EP! 625-7-RWM. Risk Reduction Enghming Laboratory and Center for Environmental Research Information, Office of Rtsuvch and Development, 1988.
United States Envin"cntal Protection Agency. Guide to PoUution hve&n.- 'Ihc Photopmessing Industry, Washington, D.C., 1990.
United States Environmental Protection Agency. Facility P o l l ~ o n Fmention Guide
G - 4 MARCH 1996
b
ERA 6@R-92-088. Cinchah ': Risk Reduction Engineering Laboratory, office of Research and Development, 1993.
United States E " t a I Protection Agency. Fedeml E n x h " a l ReguWom Potentially @ia 'ng the Commcrchl prinring Indusny EPA 74&8-93-cK)3. Washington, D.C.: Design far the Enviro"t Program, Economics, Exposure and Technology Division, offia of Pollution Prevention and Toxia, 1993.
United States Environmental Protsction Agency and Womia Department of Toxic Substances Control. Practical Pollution Prevention Techniqzus for Lithographic Printers. San Francisco, April 1994.
Virginia Department of Environmental Quality. oppOmuritics to Reducc Waste Generaion: Printing Industry R e p t 27-1. Richmond: Waste Reduction Assistanct Program, 1991.
Waterless Printing Association. The Benejh of Waterless Printing. April 1993.
Watson, Tom. "Recycling of Waste Printing InL Catches on at Newspapas. " Resource Recycling 2:1 (1988), pp. 20-21.
White, Patrick. "Is the Time Right for Direct-to-Ph." Desktop for B v J z 2:3 (March 1994), PP* 3.
G - 5 MARCH 1996
APPENDIX H
DIAGRAM OF MAJOR WASTES GENERATED BY LITEOGRAPEIC PRINTING
Major Wastes Generated by Lithographic Printing
I MATERIALS
Film Photo processing
Energy fixers & developers
IWASTES
' Film Wastewater
Silver Toner Toner cartridges Water Energy
(spent fixer/developer)
Plates: aluminum, plastic E other types Water Energy
Wastewater Aqueous developer Used plates Water Energy
WASTES FROM CLEANING PRESS EQUIPMENT: Waste solvent Cleanup towels Waste ink
Empty solvent containers vocs Wastewater
Inks: vegetable (e.g., soy & linseed),
Fountain solutions: isopropyl alcohol
Press lubricating oils, cleaners Paper Water
rubber, oil based, ultra violet
(IPA), non-IPA
Energy
Waste ink Waste paper vocs Empty ink containers Lubricating oils
Paper Glue Binding Energy (e.g., comb)
Waste paper trimmings
vocs Waste glue Energy
