Alaska Health Proiect - InfoHouseinfohouse.p2ric.org/ref/12/11250.pdf · ON-SITE CONSULTATION AUDIT REPORT: PLASTIC BOTTLE MAXING/CIIEMICAL ... Plant Operations Bottle Making ...

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Alaska Health Proiect

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WASTE REDUCTION ASSISTANCE PROGRAM (WRAP)

ON-SITE CONSULTATION AUDIT REPORT:

PLASTIC BOTTLE MAXING/CIIEMICAL MANUFACTURING

JUNE 1, 1988

FDEP I Waste Management Pollution Prevention Program Library NO.~%OO -00 fl

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READERS NOTE:

The i n f o r m a t i o n c o n t a i n e d h e r e i n i s i n t e n d e d t o b e g e n e r a l g u i d a n c e f o r t h e f a c i l i t y d e s c r i b e d i n t h i s r e p o r t a n d t h e i n d u s t r y a s a w h o l e . I t i s t h e p r o d u c t o f a p p r o x i m a t e l y 6 t o 8 h o u r s o f o n - s i t e c c c s u l t a t i o n w i t h t h e f a c i l i t y o w n e r . T h e f o c u s o f t h e r e p o r t is was te m a n a g e m e n t a n d was te r e d u c t i o n , n o t r e g u l a t o r y c o m p l i a n c e . R e g u l a t o r y i s s u e s m e n t i o n e d a r e d i s c u s s e d only i n s o f a r a s t h e y i m p i n g e o n m a n a g e m e n t i s s u e s r e l a t e d t o h a z a r d o u s w a s t e m a n a g e m e n t a n d was t e r e d u c t i o n , a n d a r e n o t p a r t o f a c o m p r e h e n s i v e d i s c u s s i o n a b o u t a l l p e r t i n e n t r e g u l a t i o n r e q u i r e m e n t s . Waste d e t e r m i n a t i o n s were m a d e from a v a i l a b l e d a t a , no o n - s i t e s a m p l i n g t o o k p l a c e . M a n a g e r s i n t e r e s t e d i n s p e c i f i c i n f o r m a t i o n o n h a z a r d o u s was te r e g u l a t i o n s s h o u l d c o n t a c t t h e n e a r e s t E n v i r o n m e n t a l P r o t e c t i o n A g e n c y o r S t a t e D e p a r t m e n t of E n v i r o n m e n t a l C o n s e r v a t i o n o f f i c e . Waste r e d u c t i o n measures a r e d e s c r i b e d b r i e f l y a n d should b e f u r t h e r e v a l u a t e d a n d b a l a n c e d a g a i n s t t h e u n i q u e c o n d i t i o n s o f e a c h s p e c i f i c b u s i n e s s .

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TABLE O F CONTENTS

Introduct ion Waste Reduction Assistance Program (WRAP) Audit Methods

Plant Operations B o t t l e Making Windshield Wiper F lu id Chemical S torage

Waste Generation B o t t l e Making Windshield Wiper F l u i d Chemical S torage

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Hazardous Materials Management Waste Storage c o s t s

W a s t e Reduction Incent ives Categories P lan t Wide Cardboard F l a t s B o t t l e Making Windshield Wiper F lu id Chemical S torage

F e a s i b i l i t y Analysis B o t t l e Making Windshield Wiper F lu id Chemical S torage

Conclusion and Summary

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8 8

8

10

11 11 12

16 16 16 17 18 18 19 20

22 22 22 23

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INTRODUCTION

W A S T E REDUCTION ASSISTANCE PROGRAM (WRAP)

The Waste Reduction Assistance Program is designed to assist

The program is small businesses reduce their industrial wastes through educational programs and on-site waste audits. funded by a RCRA 8001 grant awarded by the United States Environmental Protection Agency (EPA) to the Alaska Health Project, a non-profit organization located in Anchorage, Alaska. The Waste Reduction Assistance Program reduces wastes through on-site technical assistance audits.

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After on-site audits are conducted, individual reports are written describing the processes used and wastes produced by the particular business. reducing these wastes. through source reduction techniques and recycling. of the business remains confidential. The audits are intended to be applicable to other similar businesses in Alaska. reports are available to interested parties upon request.

This report is the result of an audit of a small

Each report then recommends methods for The audits emphasize waste reduction

The identity

Audit

manufacturing/distributing company. The purpose of the report is to :

1.

2.

3 .

Identify the wastes produced in the manufacturing of plastic bottles, .windshield wiper fluid, and chemical storage and the processes by which they are generated.

Make recommendations f o r methods to reduce the amount of waste generated.

Identify common waste management practices and advise on methods to improve the storage and shipping of hazardous waste.

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1. Analyze the cost benefits of selected strategies recommended.

waste reduction

5 . Provide an example to other manufacturers of similar products of how to conduct a waste reduction audit.

All recommendations, information, and cost data included in - ._

this report are subject to change with changing market conditions, regulatory climate, and shop processes. is written for a specific Alaskan business; it offers only

This report _ _

general guidance to other small quantity generators.

AUDIT METEODS

The audit team included an environmental engineering graduate student intern and an environmental health specialist. The audit was performed in two steps: with the shop foreman and a shop walkthrough. collected the following information:

a preliminary interview The interview

2 . Shop processes

3 . Material safety data sheets.

4 . Current waste management practices.

During the interview, the audit team explained the audit process to the shop foreman.

In step two, the shop foreman and the audit team conducted an-inspection of the shop operations and processes. The audit team identified the processes with the potential for generating waste and investigated the ShOpls waste management practices.

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I . . .

The six hours of on-site audit included no environmental sampling or industrial hygiene monitoring. Provided in this report is based on the interview, the

All the information - walkthrough, and a literature review. Any hazardous waste determinations are based upon existing laboratory reports. volume figures were based upon estimates made by the generator and the audit team during the shop walkthrough. was written by the graduate student with guidance from Alaska Health Project and University of Alaska at Anchorage School of

Waste

The audit-report

Engineering.

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PL,ANT OPEXATIONS

The main p l an t ope ra t ions inc lude production of p l a s t i c b o t t l e s and windshield wiper f l u i d , f i l l i n g p l a s t i c b o t t l e s with windshield wiper f l u i d , and chemical s torage . Minor operat ions include production and d i s t r i b u t i o n of p u r i f i e d and d i s t i l l e d water, Ice M e l t , a n t i - f r e e z e , and s p e c i a l t y chemicals. r epor t w i l l concentrate on t h e main p l a n t operat ions.

includes o f f i c e space, a b o t t l e making room, a windshield wiper f l u i d f i l l i n g a rea , and chemical and b o t t l e s to rage (F igure 1). Outside t h e bui lding are fou r 14,000 g a l l o n tanks , one 2,000

gal lon , one 700 ga l lon , and one 600 g a l l o n tank. One of the 1 4 , 0 0 0 ga l lon tanks i s used t o s t o r e methanol, another t o s t o r e g lycol , and the o the r s con ta in windshield wiper f l u i d . The

smaller tanks are used f o r mixing, n o t s torage . Following is a desc r ip t ion of t h e major processes i n t h e f a c i l i t y .

This

The p l an t s i z e i s approximately 8000 square f e e t , which

Plast ic b o t t l e s are made o u t of polyethylene and shaped by a blow molder. Three types of b o t t l e s a r e made a t the p l an t : ga l lon d a i r y b o t t l e s , gallon i n d u s t r i a l b o t t l e s , and q u a r t i n d u s t r i a l b o t t l e s .

chutes containing forced a i r t o p u l l t h e trimmings i n t o a hopper where they reenter t h e feed s tock . recyc le chutes where waste polyethylene can be inserted f o r recycle .

The p l a s t i c e n t e r s t h e blow molder as small polyethylene beads. The beads are ground and hea ted , and t h e p l a s t i c is piped t o t h e extruder where i t flows i n t o molds. Then the b o t t l e is mechanically placed onto a conveyor b e l t . The b o t t l e s cool r ap id ly while on t h e conveyor b e l t . I f t he b o t t l e s m i s s the

The blow molder i s s e t up t o recycle. I t i s equipped with

There a r e \doors on t h e

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Post Road

,

North

I B o t t l e

Windshield Wiper F ill

/J

off ice

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Making Room!

Chemical Storage

14,000 Gallon Tanks

Railroad Tracks

Figure 1 Partial Schematic Diagram of Plant

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s l o t s on t h e conveyor b e l t , they l o s e their shape and are no longer useable. Next, t h e b o t t l e s f a l l onto another conveyor b e l t where they a r e trimmed and checked f o r a i r holes. automatically f a l l i n t o r ecyc le chutes . b o t t l e s a r e pushed i n t o recycle chu te s . extruded each t i m e t he machine starts up, each weighing approximately f i v e pounds. Unusable waste is generated when t h e b o t t l e s f a l l s on t h e f l o o r , becoming contaminated w i t h d i r t and grime.

Trimmings Uncontaminated, unusable Two slugs of plast ic are

WINDSHIELD WIPER FLUID

-- The windshield w i p e r f l u i d (methanol, water, su r f ac t an t [ammonia], and dye) is mixed o u t s i d e i n a 14 ,000 ga l lon tank. The mixture i s then piped i n t o the shop and i n t o an automatic f i l l i n g and capping machine. Windshield wiper f l u i d i s pu t i n t o gal lon p l a s t i c b o t t l e s .

CBEMICAL STORAGE

Approximately 50% of t h e p l a n t space is used for chemical s torage . t o the c e i l i n g . i n bags, buckets, o r 5 5 ga l lon drums.

she lves a r e bolted t o t h e f l o o r and extend t o t h e c e i l i n g w i t h

three o r four s to rage l e v e l s . The she lves are organized based on t h e s i z e and shape of the conta iner . Chemical compa t ib i l i t i e s are unknown.

P l a s t i c bo t t l e s are s t o r e d on the f l o o r , and stacked up Chemicals are stored OR the f l o o r o r on shelves

Chemicals are e i the r s t o r e d on she lves o r on the f loo r . The

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Chemicals include water t rea tment chemicals used by t h e Municipali ty of Anchorage, old j a n i t o r i a l supp l i e s , and a v a r i e t y of miscellaneous chemicals. Water t r e a t m e n t chemicals are s t o r e d on t h e floor. Some l i f t s are separated by pa l l e t s whi le o t h e r s are separated by cardboard splits. Pal le t s a r e o f t e n beneath 55 ga l lon drums t o ease i n moving them. The base of t h e 5 5 ga l lon drums sometimes hang over t h e edge of t h e p a l l e t s and t h e drums are no t secured t o t h e pallets.

Stock on hand is excess order and is wai t ing t o be so ld . The supp l i e s a r e genera l ly s t o r e d i n f i v e g a l l o n buckets and case l o t s . Not a l l t he con ta ine r s are sealed.

J a n i t o r i a l suppl ies are no longe r s o l d by t h e company.

Other s t o r e d chemicals have been used i n t he prepara t ion of c-

s p e c i a l t y chemicals. Containers include bags, f i v e g a l l o n buckets , o r 55 g a l l o n drums. N o t a l l of t he conta iners are labeled; some of t h e bags a r e r ipped, and no t all t he con ta ine r s are sealed. Storage i s unordered. Stock i n 5 5 ga l lon drums which is n o t s t o r e d on she lves i s moved around.

Most are s t o r e d on she lves o r on p a l l e t s .

.

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W A S T E GEKERATION

Wastes are generated in the bottle making process, during filling of the bottles, and the moving and storage of chemicals. Each process generates its own characteristic waste.

Primary waste generated is plastic. Plastic waste is generated in the following ways:

1. Five pound plastic slugs are generated during start up and/or change over of the blow molder. Start'up/change over

-- occurs every two to three weeks.

2 . Plastic waste associated with imperfect molding ends up on the floor. During the audit, waste bottles were generated at a rate of approximately 15 to 20 bottles per hour,

WINDSHIELD WIPER FLUID

Most of the waste is generated by the filling machine. Waste product ends up on the floor where it is diluted with water and washed into the city sewer.

The windshield wiper fluid is 50% methanol which is a regulated substance. filling process. site prior to proper disposal. sessions estimate an average of 5 % (Figure 2 ) of the product is

The waste product is generated during the No waste is generated which has to be stored on

Calculations based on three fill

% Removed from Gallons Gallons Gallons Depth of % Area Flow ( % ) Full Storage Tank Packaged Removed Lost

66/120 = 55 56 100-44-38 = 18 2509 2590 82

2302 . 118 49/120 = 41 38 100-62-22 = 16 2185 33/120 = 27 22 100-78-18 = 4 485 576 91

26/120 = 22 18

Tota l Removed: 5468 gallons T o t a l Lost: 291 gallons

Percent Lost: 5%

Figure 2 Calcu la t ions of Product Waste

from the Fill Machine (Viessman and Hammer, 1985)

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S p i l l s occur when t h e s to rage r e s e r v o i r i n t he f i l l machine overflows, when the f i l l machine over f i l l s t h e b o t t l e s , and when t h e capper doesn ' t hit t h e center of t he b o t t l e .

1. The s torage r e s e r v o i r of t h e fill machine i s f i l l e d by a

pump. pump is n o t synchronized wi th t h e ra te a t which the pump f i l l s the tank, t h e r e f o r e , windshield wiper f l u i d s p i l l s

Overflow occurs because t h e f l o a t which regulates t h e

onto the f l o o r .

2.

--

3.

4 .

Bot t les are placed i n s l o t s on a conveyor b e l t and are f i l l e d a s they t ravel : along t h e conveyor. The f i l l e r can o v e r f i l l t h e b o t t l e s . Excess f a l l s on t h e f l o o r .

An automatic capper seals t h e always f i n d t h e center of t h e t i l t e d o r squashed during t h e ends up on t h e f l o o r .

b o t t l e s . The capper doesn' t b o t t l e and t h e b o t t l e s can be capping process . Spi l lage

After t h e b o t t l e s are f i l l e d and capped they go onto another conveyor b e l t where t h e f i l l levels and cap t i gh tness is

checked and they are prepared for shipment. When a lot of b o t t l e s s t a c k up on t h e conveyor b e l t t h e pressure between them can bu i ld up t o a p o i n t where caps g e t squeezed o f f , s p i l l i n g product on t h e f l o o r .

CHEMICAL STORAGE

Due t o a lack products are moved

of s t o r a g e area i n t h e p l a n t , chemicals and around t h e shop t o make room when more s torage __

is needed o r when s p e c i f i c s t o r a g e needs access. include j a n i t o r i a l s u p p l i e s and o t h e r chemicals of unknown composition.

it is o f t en necessary t o s t o r e l a r g e q u a n t i t i e s of b o t t l e s and

Shelf contents

Floor s torage is a problem s i n c e space is a t a premium, and

windshield wiper f l u i d .

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W A R D O U S MATERIALS MANAGEMENT

W A S T E STORAGE

A small q u a n t i t y genera tor may n o t s t o r e hazardous wastes i n q u a n t i t i e s greater than 1 3 , 2 0 0 pounds f o r longer than 180 days. The waste may be s t o r e d f o r 270 days i f i t has t o be t ransported over 200 m i l e s t o a l i c e n s e d hazardous w a s t e . f a c i l i t y . T h i s provis ion app l i e s t o Alaska, which has no approved hazardous waste d isposa l f a c i l i t y . month of hazardous wastes are subject t o t h e S m a l l Quantity Generator Regulations if they s t o r e more than 2 , 2 0 0 pounds of hazardous wastes.

Generators of less than 220 pounds per

Hazardous wastes con ta ine r s should be c lear ly labe led "HAZARDOUS WASTEft.

beginning da te of c o l l e c t i o n . good condi t ion, c losed , and in spec ted once per week. The wastes, i f i g n i t a b l e o r r e a c t i v e , should be placed a s f a r as poss ib le from t h e s t o r a g e ' s p rope r ty l i n e . on - s i t e without a permi t i f :

The con ta ine r s should a l s o be marked w i t h t h e The con ta ine r s should be kept i n

The wastes may be t r e a t e d

A ) They are treated wi th in 1 8 0 days ( i n Alaska, 270 days).

B) The con ta ine r s conform t o t h e r egu la t ion described i n t h e above paragraph.

C) Steps are taken t o prepare f o r and prevent accidents as described i n t h e Small Quant i ty Generator Regulations.

Precaut ions should be taken t o prevent acc idents involving the hazardous materials s t o r e d on s i t e . s to rage of hazardous m a t e r i a l s and wastes were w r i t t e n t o prevent acc iden ta l s p i l l , f ires, explos ions , and r e l e a s e t o t h e environment. The ope ra to r of a s i t e should develop a contingency p l an t o d e a l w i t h a cc iden t s involv ing t h e hazardous wastes being s to red .

The r egu la t ions f o r t he

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Generally, there are three acceptable disposal methods for hazardous wastes:

A. Disposal in a licensed hazardous wastes landfill.

B. Disposal in an authorized high-temperature incinerator.

C. Disposal to an authorized hazardous waste recycler.

None of these facilities are available in Alaska and all wastes must be transported to a disposal site approved by the Environmental Protection Agency (EPA). The wastes must be shipped in containers and by haulers as prescribed by the

-- DeBartment of Transportation (DOT). A hazardous waste hauler should be able to offer assistance in assuring adequate packaging. The packaging requirements are described in the DOT regulations (49 CFR part 172).

COSTS

following factors :

A. Quantity and nature of the waste.

B. Transportation distance.

C. Variations in process charged by the haulers and disposal facilities for the transportation and disposal of the hazardous wastes.

It may be advantageous to contact other generators of hazardous wastes to coordinate shipments and realize savings through bulk shipments. Waste determination fees may be eliminated if future waste Streams remain constant.

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In Alaska, there are no EPA approved hazardous waste management facilities. must be shipped out-of-state to an approved facility. of shipping the hazardous waste increases the disposal costs

A l l hazLrdous wastes, as defined by R C a ,

The cost

considerably.

hazardous wastes generated in Alaska can cost up to 1,390.00 (Glean Incorporated). a very generalized estimate which assunes incineration as the ultimate disposal method. (approved for hazardous wastes by EPA), or by recycling, costs may be reduced. depending upon the hauler and the disposal facility.

into consideration when purchasing raw materials and planning expenditures. analyzed to identity means of minimizing the generation of

Comprehensive disposal costs for a 55-gallon drum of

See Table 1 for a cost breakdown. This is

If the waste is place in a landfill

Also, as noted previously the cost can vary

The high disposal cost of hazardous wastes should be taken

Production processes and methods should also be

hazardous wastes ar-d thereby disposal costs.

Transportation

Disposal Site Profile (On site lab analysis)

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Waste Acceptance

$ 310.00

$ 200.00

$ 125.00

Incineration $ 580.00

The wastes investigated during the audit are not hazardous wastes as defined by the Environmental Protection Agency (EPA) except methanol.

from Resource Recovery and Conservation Act (RCRA) regulations pursuant to 40 CFR 261.4 (A) (1) (ii) (domestic sewage exclusion). However, the discharge must meet local requirements for discharge into the sewer system. requirements would result in the need to dispose of methanol waste in a different fashion.

Currently it appears that the methanol discharge is excluded

Failure to meet these

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The methanol waste may also be excluded under part 261.3 (D) relating to "de minimus" losses from manufacturing operations. However, it remains questionable how EPA would interpret or define the losses from the fill tank reservoir.

Through better recycling and process management the company could save money as well as reduce the load on the sanitary landfill and sewer system.

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W A S T E REDUCTION

INCENTIVES

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The private sector has many incentives to reduce their hazardous wastes; they include the following:

1. High disposal costs: strict hazardous waste legislation and high liability lead to disposal costs that are increasing every year.

2 . Financial liability: Generators of hazardous wastes are liable for their wastes from their production to their ultimate disposal. irr.;roper h a n d l i x j by the transporcer or the disposal facility, as well as any future sudden releases of disposed wastes. By reducing wastes, generators reduce their

This liability includes potential

. liability.

3 . Public relations: Hazardous waste is now a very visible issue; employing waste reduction can better a business's public image.

4. Savings of raw materials.

5. Improved safety and health conditions.

CATEGORIES

The production of wastes can be reduced in many ways. The most effective way to reduce wastes is to reduce the use of the processes and raw materials that create them. Source reduction and waste recycling are treatment methods effective to reduce wastes. Wastes which cannot be recycled should be treated on site to reduce the toxicity; or as a last option, sent to a disposal facility.

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I .

Waste reduction techniques can be grouped into the following categories:

1.

2 .

3.

4 .

Process Modification: The use of technology to reduce wastes. For example, redesigning equipment or production lines to produce less waste.

Improved Plant Operations: decrease wastes. For example, improved chemical storage to prevent spills.

Changes in plant operations that

Production Process Changes: will produce less waste.

Utilizing raw materials that

Recycling and Reuse: the production process. For example, regrinding polyethylene clumps generated at the start up of operations.

Recycling potential wastes back into

W A S T E REDUCTION OPTIONS FOR THIS PLANT

PLANT WIDE OPTIONS

Waste reduction through source reduction and recycling can offer economic benefits to a company through cost savings, reducing regulations, and treatment costs. This facility is encouraged to investigate waste reduction opportunities more fully. reduction plant-wide by:

In general the plant could identify and enhance waste

1. Inventorying all chemicals and raw materials on a regular basis to ensure against leaks and spills.

2 . Implementing formal employee training procedures to ensure proper operation and maintenance of plant process equipment. In addition employees should receive proper training in hazardous materials management and waste reduction to practice waste reduction.

3 . Conducting periodic waste audits to maintain plant efficiency, waste generation, and waste reduction.

4 . Evaluating current and future storage needs to ensure adequate space to increase plant efficiency and reduce potential for losses.

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5. Forming an in-plant waste reduction team to monitor the effectiveness of waste reduction options and identify additional possibilities.

CARDBOARD FLATS

Cardboard flats are used in the storage of plastic dairy bottles. The cardboard flats are recycled. Recycled flats are used in the storage of industrial bottles.

MAKING

Polyethylene used in the production of plastic bottles is a non-boidegradable compound. It is recyclable. By increasing the amount of raw material recycled money is saved through less l o s s of product and lowered solid waste disposal costs.

opportunities for the bottle making process. contamination of the plastic and to enhance recycling the

Improved plant operations offer l o w cost waste reduction

To prevent the

following recommendations are suggested:

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1.

2 .

3.

-- 4 .

Operate and maintain the blow molder at optimum efficiency to reduce the amount of plastic which could possibly become contaminated with dirt and grime.

Place clean baskets near locations where imperfect bottles are removed from the production line (by the extruder, and where the bottles change conveyor belts). The baskets would temporarily store plastic until the operator had the time to put the plastic into the recycling chutes.

Research the feasibility of installing additional recycle chutes.

Keep accurate records on plastic lost and recycling savings.

Air quality around the grinder and in the bottle making room may exceed the standards for particulates. determined through air sampling and analysis. polyethylene shavings was noted around the grinder as well as a plastic taste noted in the bottle making room during the audit.

This can be A large pile of

WINDSHIELD WIPER FLUID

Most of the waste associated with the windshield wiper fluid is generated by the fill machine (fill reservoir overflowing, bottle overfilling, and miss capping). be made to the fill machine process to enhance waste reduction.

Currently the shop does recycle some lost material in this process. Leaking bottles of windshield wiper fluid are removed from the production line and used to "top off" other containers to maintain a constant fill level in all the bottles. waste reduction can be achieved through equipment modifications, improved operation, and recycling.

Several improvements can

Additional

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I. Overflow losses from the fill machine reservoir can be controlled by installing a sensitive float system which will only allow the reservoir to fill to a specified level.

2 . Losses associated with the capper could be controlled by installing new equipment. needs of the facility owner. basin be installed to collect spillage.

However this does not meet the It is recommended that a catch

The product could be recycled back into the fill reservoir.

3. Extension of the conveyor rack and rapid removal from the belt would help avoid spills in this aspect of the process.

-- 4 . Additional monitoring of actual losses should be performed

to determine cost savings for waste reduction technology.

The concentrations of methanol and ammonia in the air may exceed health standards. performed to ensure compliance. A strong ammonia smell was noted

Air sampling and analysis should be

during the audit.

CHEMICAL STORAGE

Chemical storage does not directly produce waste. The limited space and constant moving of the chemicals create an environment with a high spill potential, which can result in waste generation. Another event which could initiate spills earthquakes. Inventory management and improved plant operat offer waste reduction opportunities for chemical storage. Specific recommendations include the following:

is ions

1. Reduce the amount of movement of chemicals/product.

2 . Ensure incompatible chemicals are not stored near each other. For instance, when ammonia and chlorine are combined a toxic gas is formed.

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. 3. Provide safe stable storage environments for all stored

inventory. Methanol is dangerous when exposed to heat, flame, or oxidants.

4 . Earthquakes are unpredictable and uncontrollable. Care must be taken to ensure stability of storage facilities. The shelves are bolted to the f l o o r , since they reach the ceiling they could also be bolted to the ceiling. Heavy materials should be kept on lower levels. Reactive and incompatible chemicals should be identified to avoid dangerous combinations in the event of an earthquake.

5 . An old stock associated with previously distributed c-

janitorial supplies should be sold or exchanged to make room for current stock and avoid problems associated with outdated stock or hazardous combinations of compounds.

6. Current stock should be ordered on an as needed basis. Reviewing past stock and order records may help in projecting future needs.

7. One potential spill problem is associated with the constant movement of chemicals and product stock in the plant. limited space requires the constant shuffling of product and stock to assure accessibility to specific items at specific times. The practice increases the chances f o r spills.

The

8. Evaluate storage needs and inventories, including future projections. Additional space may be warranted.

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F E A S I B I L I n ANALYSIS

Gallon b o t t l e s con ta in approximately 63 grams of polyethylene. waste polyethylene a r e generated. $0.50 per b o t t l e , $ 3 6 . 0 0 worth of raw material is l o s t . add i t iona l loss of 15-20 b o t t l e s w e r e wasted during the aud i t . This y ie lds a raw material l o s s of $5,100.00 t o $ 6 , 3 0 0 . 0 0 per month assuming 2 4 hour a day 7 day per week production, and waste generation r a t e s s i m i l a r t o those observed dur ing t h e aud i t .

P l a s t i c laundry baskets c o s t about $5.00 apiece. I f four were placed around t h e blow molder and molded b o t t l e l o s s was c u t by SO%, t h e c o s t of t h e baskets could be realized i n one hour.

Every two t o three weeks, two f i v e pound clumps of A t an approximate c o s t of

An

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WINDSHIELD WIPER FLUID-FILL MACKINE

The problem off o v e r f i l l i n g t h e r e s e r v o i r i n the f i l l machine can be resolved by i n s t a l l i n g a more s e n s i t i v e f l o a t system which w i l l shu t t h e pump off p r i o r t o overflow. t o Dice Pump and Well Supply and Alaska Pump and Supply these systems are a v a i l a b l e f o r under $50.00 , system would be paid f o r by t h e sav ings i n product from one f i l l session.

I f t h i s i s not f e a s i b l e a c o l l e c t i o n r e s e r v o i r t o t r a p overflow from fill machine processes should be considered. t he c u r r e n t l y ca l cu la t ed product l o s s , the payback per iod could be r e l a t i v e l y sho r t .

According

The p r i c e of t h e f l o a t

Given

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Recommended waste reduction options for chemical storage can be implemented at little cost. Most recommendations involve management and procedural changes.

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CONCLUSIONS AND SUMMARY

The waste streams inves t iga t ed during t h i s a u d i t are not regulated as hazardous waste. T h i s p l an t does produce and s t o r e hazardous materials.

T h i s p l a n t a l ready a c t i v e l y recyc les some of i t s waste. Cardboard f l a t s a r e reused, leaky bot t les of windshield wiper f l u i d a r e used t o maintain cons tan t fill l e v e l s , and some of t h e unusable b o t t l e s and a l l of t h e trimmings a r e recycled by the blow molder.

Recycling can be extended by:

Baskets around t h e blow molder t o reduce p l a s t i c contamination t o enable recyc l ing .

I n s t a l l a t i o n of a s e n s i t i v e f l o a t i n the r e s e r v o i r of the f i l l machine t o prevent overflow.

Addition of an apron or holding tank under t h e fill machine t o ca t ch overflow and r ecyc le it back i n t o t h e r e se rvo i r .

1. --

2.

3 .

Chemical storage can be improved by:

Stock only chemicals c u r r e n t l y i n use

Provide permanent s t a t i o n a r y stable s torage areas.

Provide adequate spacing between incompatible chemicals.

1.

2 .

3 .

4 . Remove obsole te s tock.

The a i r q u a l i t y i n t h e b o t t l e making room and the windshield wiper f l u i d fill area should be checked fo r p a r t i c u l a t e s and d”onia/methanol r e spec t ive ly t o ensure they comply wi th State OSHA standards. Request a s s i s t a n c e from t h e S ta te Department of Labor. Voluntary Compliance Sec t ion ( 2 6 4 - 2 5 9 9 ) . p r o t e c t i v e

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clothing may be necessary when working with methanol. employees should be trained on the possible effects of the compounds they work around and what to do in case of an accident. Contingency plans need to be set up outlining the procedures to be followed in the event of a spill.

but not limited to fire extinguishers, first aid kits, and eye wash stations. from the shop that the floors do not become slippery due to snow melt in the winter.

in this report are relatively inexpensive and easy to implement. Savings of raw material and product would cover the costs of implementation in a very short time. Through this audit and the solutions presented herein it should be possible to increase the productivity of this plant.

waste management team composed of workers and management to further evaluate and identify waste reduction opportunities. Moreover, this team would serve as a vehicle for measuring the success of any waste reduction option that is implemented.

A l l new

Emergency equipment should be present in the plant including

Care should be taken at the entrances and exits

The majority of waste materials management options suggested

c-

It is strongly recommended that this company form a internal

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SELECTED REFERENCES

Alaska Pump and Supply, 261 E a s t 56th Avenue, Anchorage, Alaska, 99518, 277-4313.

Dice Pump and W e l l Supply, 237 North Orca, Anchorage, Alaska, 99501, 563-3424.

Glean, Incorporated --

Resource Recovery and Conservation A c t , 40 CFR p a r t 261, July 1, 1987.

Viessman, Warren and Hammer , Mark, 1985. Water supply and p o l l u t i o n c o n t r o l , 4th ed. Harper and Row, New York, pg 173.