Pollution Prevention Commercial Printing Fact Sheet Office of Pollution Prevention

P2 for the commercial printing industry

The commercial printing industry generates hazardous waste as a result of its operations. The Virginia Department of Environmental Quality regulates the generation, treatment, storage, transport and disposal of hazardous waste througout the Commonwealth. DEQ is committed to reducing hazardous waste generated to the greatest extent possible.

As part of this effort, studies investigating alternative management strategies to reduce hazardous waste have been completed. This fact introduces the hazardous waste audit study conducted specifically for the commercial printing industry. Many companies today have incorporated these options into their overall operations and are saving money on hazardous waste management costs while protecting their workers and the environment.

Waste streams typical of the commercial printing industry

• Waste photochemical solutions and films (e.g., some negative developers for lithography are classified hazardous as products and may also be hazardous as wastes under state regulations).
• Waste inks containing hazardous components (often metallic pigments and solvents).
• Ink-contaminated solvents and rags used for cleaning.
• Lubricating oils from machinery.

Waste reduction incentives

Hazardous waste reduction can be an effective, economic way to reduce waste management costs. In some instances, waste reduction may require some initial capital investment, but many companies have shown that, even in the short term, they may quickly recover these up-front costs when hazardous waste management and liability costs are reduced. Other advantages include:

• Reduced tax burden from generator fees, land disposal fees and taxes.
• A safer workplace for employees.
• Reduced threat to the environment and compliance requirements.
• Improved corporate image in the community.

Waste reduction alternatives

What can you do to reduce hazardous wastes at your shop? Start with good operating practices.

Management commitment

An important aspect of any pollution prevention program is management commitment. Commitment shows employees that managers place a high priority on waste reduction. For example, a conspicuously posted shop policy, signed by top management, that requires waste reduction will aid in making pollution prevention a critical part of all day-to-day activities. All employees must be encouraged to participate in reducing wates to the greatest extent possible.

Also, if an employee is placed in charge of identifying ways to prevent pollution, he or she must be given the cooperation, by both employees and management, necessary to implement pollution prevention techniques and strategies in shop operations.

Employee awareness

Management should solicit and encourage suggestions from employees through a merit program or some other type of incentive. From the owner/president of the company to each machine operator, pollution prevention efforts should be emphasized to every employee.

Good housekeeping

• Segregate wastes to increase recyclability.
• Keep careful records of inventory control. 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.
• Label contents, and expiration dates should be legible.
• Designate one person, usually the shipping and receiving clerk, to manage raw materials for proper inventory control to ensure that hazardous substances are properly contained and labeled, and to confirm that a Materials Safety Data Sheet (MSDS) is on file.
• If materials have exceeded their shelf-life, check on alternative uses before discarding. Consider contacting nearby theater groups or college graphic arts departments to donate expired materials for their programs. Also, buy from a manufacturer that will accept materials back if shelf-life is exceeded.
• Minimize spills and use dry methods for cleanup wherever possible. If a spill of a hazardous substance occurs, use an absorptive material to soak it up, and dispose of it in accordance with all local, state and federal regulations.
• Monitor press performance continuously to minimize bad runs and waste. Detectors and other equipment are commercially available for this use.
• In larger businesses, make sure hazardous waste-generating departments are billed for management, compliance and disposal costs incurred by their activities. Hazardous waste management costs covered under a general expense fund do not give specific departments an incentive to reduce their wastes.
• Be innovative in trying new procedures and products.
• Find ways to use paper. Make notepads, postpaper or other products from extra paper. Recycle all paper waste or donate it to schools and churches. Recycle aluminum plates, negatives and any other silver-laden paper.

Silver compounds are classified as hazardous wastes under state and federal law if liquid wastes exceed five milligrams per liter of silver at a pH of 5.0. If process baths are discharghed into the sewer, a permit by the local sanitation department is usually required. Concentrations of silver-contaminated wastewater must be maintained below local limits established by each sewering agency.

Ways to manage silver

• Eliminate by using silver-free films. Some silverless products are vesicular, diazo and electrostatic films. Photopolymer films contain carbon black as a substitute for silver.
• Recover silver from fixing baths and have a commercial recycler pick it up. Purchase a silver recovery unit and recycle fixer on premises.
• Add ammonium thiosulfate to silver-contaminated baths to extend the allowable buildup of silver.

Process baths

• Use an acid drop bath prior to the fixing bath. This action reduces the effect of an alkaline developer on the fixing bath pH. Add acetic acid to the fixing bath, which will keep the pH low to maximize soluble complexes.
• Use floating lids on bleach and developer containers to keep them fresh.
• Install waterless paper and film developing units to reduce the volume of fixer water. Segregate fixer from developer waste.
• Substitute non-hazardous raw materials for hazardous materials whenever possible.
• Install electronic imaging and/or laser plate making. By editing on a video terminal, the need for photgraphing and re-shooting can be reduced. This alternative is costly, so make sure the period is evaluated before purchase.
• Employ countercurrent rather than paralell 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 much of the contamination is already rinsed off the film.
• Protect process baths that spoil easily by keeping them containerized. Small-scale photo developers can containerize process baths and use glass marbles to bring the liquid level to the brim each time the liquid is used.
• Use personal computers with commercial publishing capabilities to allow the user to set up and edit jobs before going to print. Materials, time and waste are reduced from draft to the final product.

Plate processing

Replace metal etching processes, with their associated hazardous chemical solutions and heavy metals, wherever possible.

Advantages of ultraviolet inks

• Dry quickly when exposed to ultraviolet light.
• May remain in ink fountains for long periods without drying.
• Eliminate set off, thus avoiding the need for anti-offset sprays.
• Eliminate ventilated storage of sheets during oxidative drying.

Advantages of electron beam (EB) drying

• Similar in use to ultraviolet inks.
• Uses less solvent than heat-set inks.

Ispropyl alcohol

Use a fountain solution that contains low concentrations of isopropyl alcohol (IPA) or one containing no IPA. IPA emissions can cause air pollution problems and may require the installation of pollution control equipment. Substitutes are available. Operation adjustments may be required to make low-IPA solutions work well, but the alternative cost of air pollution control equipment installation can make the effort economically worthwhile.

Waste solvents

Rags become contaminated with ink and solvent. Depending on the solvent used, contaminated, non-saturated rags amy not be considered hazardous waste by the federal and state government if they are laundered and reused. However, contaminated rags to be disposed may be considered hazardous. These diposable rags must be stored separately from municipal trash and transported according to hazardous waste regulations.

Solvent alternatives

• Use soap or detergent solutions wherever possible. Employ solvents only for cleaning inks and oil.
• Employ specially made blanket washes that do not contain hazardous materials.
• Use small solvent recovery systems currently on the market, which work well.
• Employ acetic acid based cleaners, which are less toxic than other solvents.

Waste lubricating oils

Used lubricating oils should be analyzed to determine if they must be managed as hazardous waste.

This Pollution Prevention fact sheet is reprinted with permission from the California Department of Health Services, Toxic Substances Control Program, Alternative Technology Division. Modifications have been made to tailor this fact sheet for use in Virginia.

This fact sheet is provided as a service of the Office of the Pollution Prevention, a non-regulatory, technical assistance program of the Virginia Department of Environmental Quality. For more information on opportunities to reduce waste, contact:

Office of Pollution Prevention
Virginia Department of Environmental Quality
629 East Main Street, 5th Floor
P.O. Box 10009
Richmond, Virginia 23240-0009
(804) 698-4545, FAX (804) 698-4346
e-mail: rtgriffin@deq.state.va.us

 

---

Updated 9/29/97