A GUIDE FOR REDUCING AlR POLLUTION FROM PRlNTlNG

Pollution prevention is the wave of the future. It is government policy. Customers want it. Common sense demands it.

However, pollution prevention won't be accomplished by government experts, paid consultants or environmental groups. It depends on you, the worker, the consumer, the manager and the citizen.

All of us are called to rethink every aspect of production with pollution prevention as a goal. Your innovation, enthusiasm and ideas will help all of us move forward to a cleaner, safer and healthier future.

POLLUTION PREVENTION & ENVIRONMENTAL MANAGEMENT

A facility can become both environmentally friendly and cost efficient by establishing a pollution prevention program. Effective practice can limit some typical business expenses and help avoid environmental compliance costs. In addition to reducing waste generation in our air, water and land, pollution prevention practices can help you gain an economic edge over competitors by:

• Reducing waste management costs;
• Improving worker safety, which means decreased workers compensation claims or sick time;
• Decreasing liability costs due to future offsite clean-up and increased property values;
• Resulting in higher productivity, increased revenues and possibly gains in market shares.

A. Inventory Control

There are often instances where materials break down during extended storage time and become hazardous wastes. To avoid having to dispose of unused materials, incorporate the following into your procedure:

• Order materials on an as-needed basis.
• Mark purchase date on containers and monitor inventory to assure that older materials are used first.
• Consider substituting non-hazardous materials for hazardous materials.
• Purchase the smallest amount of solvent and other chemicals to do the job; waste disposal costs for unused chemicals may be higher than the savings of buying materials in bulk quantities.
• Seek a multi-purpose solvent or cleaning chemical rather than several different solvents; this will increase the chances of getting your waste recycled.

B. Record Keeping

Record keeping is an important tool of environmental compliance. Keep track of every receipt, bill, and all manifests every time you dispose of waste. Keep records of the waste hauler company, recycler, and storm water permits (if applicable) always on file. MSDS of all chemicals used in the facility should be readily available for reference.

Record keeping can also become an integral part of any pollution prevention program. After implementing your program, evaluate records to identify source reductions.

C. Employee Training

Even the best waste handling arrangements can fail unless workers are involved in and committed to carrying out the plans. It is important that employees are aware that the cost of a job or project is influenced by how they handle materials that will become hazardous wastes when used. Employee training should stress:

• The need to use a minimal amount of solvents or other chemicals.
• The importance of reading Material Safety Data Sheets (MSDS). These sheets give key environmental, health and work place safety information. Reading an MSDS before making a purchase could help avoid problems down the road.
• Proper training can provide a safer and healthier workplace.
• An employee training program will also enhance public image for your business and reduce liability as well as show your customers and employees that you are taking extra steps to make your workplace better.

D. Good Housekeeping

Good housekeeping includes spill prevention as well as efficient use of raw materials. The following are good housekeeping practices:

• Always segregate wastes to increase recyclability. By mixing hazardous wastes with non-hazardous wastes, the entire volume may be considered hazardous waste, which increases disposal costs.
• Designate one person to manage raw materials and to ensure that hazardous waste materials are properly controlled.
• If the materials have exceeded their shelf life, return it to the manufacturer.
• Keep equipment in good working condition. Preventive maintenance and regular inspections for proper operation will reduce the likelihood of a bad batch. Minimize spills and use dry methods for cleanup whenever possible.
• Always keep containers with processing materials and solvents closed when not in use to prevent valuable materials from evaporating.
• Be innovative, try new procedures and products. For example, reuse paper by making it into notepads.

Prepress can be divided into two steps: image processing and image transfer. Image processing involves photoprocessing, while image transfer involves preparation of a plate from a photographic negative or positive. The primary wastes are processing chemicals, silver and waste water. Some of the pollution prevention options are as follows:

1. Material substitutions

• Discontinue use of etched plates. Use dry positive proofs, aqueous developed proofs, or water developed plates.
• Eliminate the use of silver by switching to silverfree films such as diazo, vesicular, photopolymer, electrostatic or selenium based films.
• Ask vendors for non-hazardous chemical substitutes to replace intensifiers and reducers that contain cyanide salts. Also use non-hazardous developers and finishers.

2. Silver Recovery

• Recover silver from fixing baths and have a commercial recycler pick it up.
• Install an electrolytic deposition for silver recovery from fix solutions. For large volumes, install an ion exchange unit.
• Add ammonium thiosulfate to silver contaminated baths to extend the allowable build up of silver (consult the chemical manufacturer first).

3. Process Baths

• Use an acid bath prior to fixing bath. This reduces the effect of alkaline developer on the fixing bath pH. Add acetic acid to the fixing bath, keeping the pH low to maximize soluble complexes.
• Use floating lids on bleach and developers to keep them fresh. Adding marbles to bring the level of partially used chemicals to the top will lessen chemical oxidation.
• Substitute non-hazardous raw material for hazardous whenever possible. Install waterless paper and film developing units to reduce the volume of fixer waste. Segregate fixer waste from developer waste.

4. Wastewater Reduction

• Employ countercurrent rather than parallel rinse techniques. Countercurrent rinsing means water from previous rinsing is used in the initial film washing stage. Fresh water enters the process at the final rinse stage, at which point many of the contaminates are already rinsed off the film.
• Use rinse bath agitators or automatic flow controls for the rinse water and recycle the rinse water.

5. Electronic Technology

• Use computers with commercial publishing capabilities to allow the user to set up and edit jobs before printing. Materials, time and waste are reduced from draft to final product.
• Use digital technology to eliminate even more prepress waste than desktop publishing by directly transferring a computer generated image to the plate. Contact vendors for more information.

F. Printing Inks

Printing inks are a major source of hazardous waste. The composition of the ink varies widely. Some inks contain chemicals (metals) that would be classified as hazardous, others do not. Color changes, press cleaning and poor ink management generate waste ink. Good operating practices can decrease amount of waste ink generated. Some good practices are:

• Keep ink containers sealed and contents leveled. Place plastic bags or waxed paper on top of the ink to prevent oxidation.
• Scrape as much ink as possible from empty cans prior to disposal or recycling.
• Use a standard ink sequence for process colors.
• Schedule runs from lighter to darker colors to decrease the amount of cleaning necessary.
• Recycle light colors into darker and specialty colors.
• Substitute petroleum-based inks with vegetable or soy inks, UV curable inks, or waterless inks. Contact vendors for more detailed information.

G. Dampening System

Fountain solutions are generally replaced when ink changes color or during maintenance. Isopropyl alcohol (IPA) is used most commonly as a constituent of the fountain solution. Some pollution prevention opportunities include:

• Eliminate the used alcohol fountain solutions such as IPA.
• Extend the life of the fountain solution by adding filters, chillers and recirculating systems.

H. Press Cleaning

Cleaning solutions are predominantly petroleum based and contain up to 100% VOCs. Cleaning the press generates wastes such as waste cleaner with residual ink, waste ink from the ink fountains, rags containing the cleaner and ink and air emissions from the cleaners. Some pollution prevention alternatives are:

• Substitute high VOC cleaners with low VOC cleaners containing no more than 30% VOC by weight. Use those with a lower vapor pressure and higher flash point. Contact the manufacturer for more details.
• Automatic cleaning systems reduce cleaner consumption by removing excess ink. These systems also prevent ink buildup which requires stronger cleaning solutions.
• Try to use one type of solvent for all purposes. This will improve recycling capabilities and decrease disposal costs.
• Collect used rags in a separate can. Use launderable rags instead of disposals. As long as the rags are just wet, not soaked, laundries will accept them for cleaning.
• Schedule jobs by color. Clean the ink tray only when changing colors.

Recycling a waste that can be recovered and reused in the same production process on site as input is a form of pollution prevention. For instance, solvent recovered from the recovery system can be reused for various purposes. Also certain types of waste generated usually have good market demand. For example, there is steady demand in the market for waste signatures, millbroke, corrugated cardboard, precious metal and spent negatives. Information on marketing wastes can be available from yellow pages (generally under recyclers, metal collectors, precious metal collectors, solid waste brokers etc.), various state solid waste agencies, regional and national waste exchange services, or through the solid waste haulers.

If you need more information on pollution prevention, please contact the Small Business Environmental Assistance Program (SBEAP) at (602) 506-5150.

10 TIPS FOR SUCCESS IN ENVIRONMENTAL MANAGEMENT

1. Establishing a pollution prevention program

The first step is to recognize the need for waste reduction at your facility and it is essential that you secure the staff commitment to achieve source reduction and recycling goals. Each step can be as basic or complex as you feel is necessary to meet the environmental goals that you set for your facility. Emphasis should lay on the fact that, the less waste generated, the less it is regulated and the more you save.

2. Evaluating pollution prevention options

Identify the opportunities at your facility that can reduce or eliminate waste generation, emissions and environmental damage. Switching to electronic imaging, using pump bottles or plunge cans for solvent, changing over to washes and fountain solutions, are all examples of ways to prevent or reduce pollution. Also always look for options to recycle your scrap film, plates, make-ready inks and any other waste streams. Wastes that cannot be reduced at the source or recycled should be disposed in accordance with the DEQ regulations.

3. Segregate your facility's wastes

It is highly recommended to keep hazardous and non-hazardous wastes separate. Do not mix solvents with other wastes generated in the facility. Mixing wastes increases treatment costs and makes recycling more difficult.

4. Dispose hazardous waste properly

Never put hazardous waste into the dumpster. Put all the hazardous wastes in one area. Be sure to separate your waste storage area from your product storage area. Label each of your containers, for example: waste ink only, used towels only, used fixer only, etc. Do not discharge any wastes into the sewer system without proper consent of the local sewer agency.

5. Prepress: Image Processing & Transfer

Waste associated with the prepress operations include damaged plates, developed film, acids, alkalis, solvents, plate coatings and developers, dated materials and rinse water. Therefore the primary pollution prevention program should project on photographic chemistry management and to recycle used plate. Other options include proper material handling and storage, material substitutions, recovery of silver, waste water reduction or even process changes to electronic technology.

6. Substitute High VOCs with Low VOC substitutes

The major cause of air emissions in the priming industry is high VOC in fountain solutions, solvents, cleaners and other chemicals. High VOC containing solutions evaporate very rapidly at room temperature, thus resulting in excess air emissions and increasing material consumption. Considering a switch to low VOC containing solutions will reduce air emissions and also result in a savings of decreased material consumption. There are many low-VOC or non-VOC products available. It is highly recommended that you work with the vendors to find products with lesser VOC contents.

7. Emerging technologies

New technologies are significantly changing the printing industry. Most processes these days can be generated by computers. Developments such as waterless printing have been seen as a possible replacement to the dampening system. New digital presses no longer needing plate processing have also been developed. New technologies have the potential not only to provide a high quality product, but also can reduce printing waste significantly furthering the cost effectiveness.

8. Recycling the waste

Although eliminating or reducing the waste is always the best option, recycling the waste is also an important element in your effort in developing a pollution prevention or waste minimization program. Often recycling programs are instituted at a facility without clearly identifying where the recycles can be marketed. Sources for such information are yellow pages under recyclers, metal collectors, solid waste brokers etc., state, regional and national waste exchange services.

9. Record Keeping

Record keeping is an important step towards environmental compliance. Keep every record of any purchase, every receipt, bill of lading or manifest every time you dispose of your waste. Keep records of sewer discharge limits and how you are meeting them. A good record keeping system can help determine the various sources of waste generation and provide answers for implementing a pollution prevention program.

10. It's in your best interests

Through the implementation of the pollution prevention program, you will be joining other lithographic printers who are taking pride in complying with the county regulations and avoiding costly penalties and fees. For more information please contact the Small Business Environmental Assistance Program at (602) 506-5150.

The following "do's" and "don'ts" may save you money and help you achieve a better pollution prevention program.

DO:

Switch to non-aerosol products, such as manual pump cans or bottles, especially if they can be refilled.

Return defective cans back to your supplier.

Purchased developer containing less than one percent hydroquinone. Check with supplier or look on your MSDS.

Make sure employees know that unused developer may be a hazardous waste.

Consider changing from a petroleum oil-based ink to a vegetable oil-based ink such as soy or linseed oil.

If using colored inks, ask your vendor for inks that contain little or no heavy metals. Ask if your vendor can re-blend waste inks.

Work with your vendor to find the lowest VOC press was that still works for you.

When storing cans of ink that have been opened, cover the ink surface with waxed paper, lids or other covers to reduce skinning an maintain ink quality.

DON'T:

Don't buy aerosol containing "listed" compounds. Work with your vendor to find alternatives.

Don't throw non-empty cans into the garbage.

Don't dispose of unused or past shelf life developer to the sanitary sewer unless you have permission from your local sewer utility.

Don't give up. When trying a low or non-alcohol fountain solution, you may need to experiment to find the right product or formulation. If one doesn't work, try another. Keep with it until you find one that satisfies you.

Don't put hazardous inks in the garbage. Handle and dispose of them as hazardous waste.

Don't pollute the air by setting your ink cleanup trays out to dry. Put ink cleanup sludges into a container with the lid sealed when not in use.

Don't mix solvents with any other waste. Keep different types of solvents in separate, labeled, closed containers.

Don't saturate shop towels with too much press wash. Use the minimum amount needed to do the job. Excessive use increases the amount of wash that needs to be bought resulting in increased air pollution.