waste reduction manual for lithographic and screen printers · 2018. 6. 13. · i. introduction a....

Waste Reduction Manual For Lithographic And Screen Printers

Printing Industry Association of the South

Tennessee Department of Environment and Conservation

The University of Tennessee's Center for Industrial Services

Tennessee Valley Authority

! Waste Reduction ! Manual For ! Lithographic And Screen Printers

: Prepared By:

1 Richard J. Jendrucko, Ph.D. : Thomas N. Coleman, M.S. : Todd M. Thomas, B.S.

Department of Engineering Science and Mechanics . The University of Tennessee

: in cooperation with:

Center for Industrial Services The University of Tennessee

1 Tennessee Valley Authority

. Printing Industry Association of the South

- Tennessee Department of Environment and Conservation

- OmbudsmanlSmall Business Assistance Program

Waste Management

1 August 1994

: TABLE OF CONTENTS

: I. Introduction ........................................................................................................ 1 : B. Disclaimer ................................................................................................................ 1 . A. Purpose of This Manual ............................................................................................ 1 .

: 11. Regulatory and Technology Trends in the Printing Industry ................................ 3

B. The United States Printing Industry .......................................................................... 6 . C. Technology Trends in Printing ................................................................................... 6

A. Regulatory Outlook .................................................................................................. 5 .

. 111. Waste Reduction Incentives for the Printing Industry ........................................ 9 . A. Tangible Direct Cost Savings ................................................................................... 11 . B. Intangible Cost Savings and Other Incentives ......................................................... 11 C. Improved Efficiency and Competitiveness .............................................................. 12 .

A. Resource Conservation and Recovery Act (RCRA) ................................................. 15 : C. Clean Water Act (CWA) .......................................................................................... 16 .

: V. The Lithographic Printing Process and Associated Waste Generation ............... 17 : A. Background ............................................................................................................ 19 : B. Overview of Lithographic Printing .......................................................................... 19 . C. Common Waste Disposal Practices for Lithographers ............................................. 21 :

VI. Waste Reduction and Recycling Opportunities for Lithographic Printers ......... 23 : B. Waste Reduction Through Inventory Controll ........................................................ 26 . C. Waste Reduction Measures for Image Processing1 .................................................. 27

. IV. Regulations Potentially Affecting Printers Waste Management Strategies ........ 13 .

B. Clean Air Act (CAA) ............................................................................................... 15 .

A. Introduction ............................................................................................................ 25 .

Opportunities for RecyclingUsed Fdm and Paper ................................................ 27 . Opportunities to Reduce the Toxicity and Quantity of Wastewater Effluent ......... 28 . Opportunities for Repress Operations Process Change ....................................... 31 : Opportunities for lmproved Photoprocessing Chemicals Storage and Handling .. 32 *

D. Waste Reduction Measures for the Platemaking Process ......................................... 32 . Opportunities for Recycling Aluminum Plates ..................................................... 32 : Opportunities to Reduce Platemaking Wastewater Volume ................................. 33 . Opportunities for Waste Reduction through Press Modifications .......................... 33 . Opportunities for Alternative Ink Use .................................................................. 34 : Opportunities dor Reducing Press Clean-up Waste ............................................. 36 . Opportunities for Recycling Spent Solvent .......................................................... 38 . Opportunities for VOC Reductions from Fountain Solutions ............................... 39 :

: A. Background ............................................................................................................ 43 .

: VII. The Screen Printing Process and Associated Waste Generation ..................... 41

B. Common Waste Disposal Practices for Screen Printers ........................................... 45 :

VIII. Waste Reduction Opportunities for Screen Printers ...................................... 47 : B. Waste Reduction Through Inventory Control .......................................................... 49 : C. Waste Reduction Measures for Image Processing .................................................... 49 : D. Waste Reduction Measures for the Screen Printing Process..................................... 49

Opportunities for Reducing Screen Reclamation Waste ....................................... 49 : Opportunities for Press and Screen Cleaning Waste Reduction ........................... 51 :

A. Introduction ............................................................................................................ 49 .

.

Opportunities for VOC Reduction ....................................................................... 51 .

. Appendix 1. Bibliography ...................................................................................... 53 . Appendix 11. Overview of Hazardous Waste Generator Status ............................... 57 : Appendix 111. Code of Federal Regulations Titles Applying to Printers .................. 59 :

A. RCRA Titles that Apply to Printers .......................................................................... 59 : B. Clean Water Act Titles that Apply to Printers ........................................................... 59 .

Appendix IV. Sources for Information on Tennessee State Hazardous Waste Regulations ................................................................................................. 61 . Appendix V. RCRA Solvents ................................................................................. 63 .

A. Currently Listed Solvents ........................................................................................ 63 . B. Solvents for Possible Future Listing ......................................................................... 63

Appendix VI. Sources of VOC’s in the Printing Industry ....................................... 65 .

Appendix VII. Detailed Printing Processes Descriptions ....................................... 67 .

2. Plate-Making .................................................................................................. 68 : A. Lithographic Printing .............................................................................................. 67 .

1. Image Processing ........................................................................................... 67 : 3. Printing .......................................................................................................... 69 . 4. Finishing ........................................................................................................ 70 .

B. Screen Printing ....................................................................................................... 71 : 1. Image Processing ........................................................................................... 71 . 2. Screen Making ............................................................................................... 71 . 3. Printing .......................................................................................................... 71 : 4. Screen Reclamation ....................................................................................... 72 :

Appendix VIII. Sources for Assistance .................................................................. 73 : A. Publication Sources on Pollution Prevention in the Printing Industry ...................... 73 : B. Agencies Providing No Cost, Hands-on Technical Assistance ................................. 74 . C. National Printers Associations ................................................................................. 75 .

Appendix IX. Selected Equipment Vendors and Printing Industry Chemical Suppliers ............................................................................................... 77 .

I. Introduction

A. Purposeof This Manual This manual was prepared for use by small to medium size lithographic and screen

printing facilities to provide general information and guidance on waste reduction. It is intended to be a quick reference guide for plant personnel on the regulation of printing wastes and a source of information on pollution prevention measures. This is a waste "problem solving" manual on which a pollution prevention program can be established. The waste reduction measures presented herein have been generalized for standard printing operations and in many cases it is likely that additional information will be required before specific measures can be implemented. For this reason many sources for additional information are cited throughout this document.

B. Disclaimer Neither the Printing Industry Association of the South, the Tennessee Valley Authority,

the State of Tennessee, the University of Tennessee or affiliates assume any responsibility for erron and/or emissions for this manual. This handbook material is not intended as a recommendation of any particular waste reduction technique, method, or process disclosed in this document. Rather, this handbook is offered for education and informational purposes and is advisory only.

form. This material may be reproduced for educational purposes with credit given to The University of Tennessee and Tennessee Department of Environment and Conservation.

recommendation of use.

This material is a public domain document. As such, it may not be copyrighted in any

Mention of trade names or commercial products does not constitute endorsement or

Special thanks to the following people for participation in the review, printing, and distribution of this manual.

Steve Hillenbrand, Tennessee Valley Authority Karen Kennamer, Tennessee Valley Authority Linda Sadler, Tennessee Department of Environment and Conservation Bob Sims, Printing Industry Association of the South George Smelcer, University of Tennessee

1

Regulatory and Technology Trends in the Printing Industry

3

: 11. Regulatory and Technology Trends in the Printing Industry

A. Regulatory Outlook As is widely appreciated, "environmentaliim" is currently a popular concept in the U.S.

Consequently, there has been a growing interest nationwide to identify polluting activities and to - reduce their effect on the environment. Regulatory agencies, in particular the US. Environmen- : tal Protection Agency, have moved vigorously in recent years to establish programs which move

away from the traditional approach of managing waste at the "end of the pipe" to preventing its * production at the source. Many current regulatory programs are based on law, while others are

voluntary programs which aim to assist and encourage those responsible for generating pollut- : ants to reduce waste.

Manufacturing facilities have been recognized as one of the major sources of pollution in the U.S. Regulatory agencies have given particular attention to wastes generated by the most

: polluting industries and many environmental laws target their manufacturing processes. Gener- ally, industries which fall in this category utilize hazardous chemicals in their operations. H o w

* ever, federal and state regulators have begun focusing on industries generating large quantities of hazardous waste on an industry-wide basis but generate small amounts at individual sites.

: Obviously, this result has or will have a direct affect on many printing companies.

- the past are faced with new regulations. In addition, under the Tennessee Hazardous Waste . Reduction Act of 1990, Tennessee companies that are classified as Small Quantity Generators : (SQGs--see Appendix 11, pg. 44) must have completed a hazardous waste reduction plan by - January 1,1994 for each of their hazardous waste streams. On the federal level, the Pollution - Revention Act of 1990 established pollution prevention as a national objective. Many very : small companies may still be exempt from most regulations. However, owners and managers : should see the "writing on the wall" and realize it will not be long before the smallest companies

Under the 1990 Clean Air Act amendments, many facilities which had been exempt in

will be targeted for regulation. The best way to avoid regulation is to reduce or eliminate waste production. Printers

have traditionally used relatively large quantities of organic solvents and inks containing heavy * metals. Of particular concern are volatile organic compound (VOC) emissions from ink curing, + fountain solutions, and press cleaning. Even though waste quantities may be relatively modest : for a small printing company, the industry on a whole produces a large quantity of waste. The

printing industry produces a large volume of waste that is emitted into the atmosphere, discharged into the waterways, or disposed of onto land. It is likely that waste regulations impact-

. ing printers will increase in number and severity in the near future. Thus, it is prudent for all : printers to reduce their use of hazardous materials and to modify operations to reduce or elimi- * nate waste generation. The information in this manual will assist you in reaching these goals.

5

11. REGULATORY AND TECHNOuxjY TRENDS IN THE P m G INDUSTRY

B. The United States Printing Industry The commercial printing industry in the U.S. is comprised of more than 80,OOO estab- :

lishments nationwide. These companies perform a wide range of functions from printing decals : on T-shirts to printing books and newspapers. They comprise the largest conglomerate of small businesses in the domestic sector with nearly 80% of the companies employing 20 people or : less. The majority of these small firms serve local and regional markets.

Lithography, letter press, flexography, gravure, and m e n printing account for about 97% of the market. Lithography and screen printing account for approximately 47% and 3%, respectively. The industry as a whole is expected to grow about 4.5% annually between 1994 and 2000 (l)*.

. :

C. Technology Trends in Printing The printing industry, among others, is entering a period of change which will revolu-

. tionize industrial practices. Driving this change is the emergence of more efficient processes, a : new sense of environmental responsibility, current and future environmental legislation and a : need to remain competitive in a dynamic marketplace. Some of the changes in the major print- - ing processes include (1):

*

.

PREPRESS OPERATIONS Adoption of computer-based Front-End Platforms (FEP’s) which allow printers and .

customers to create entire documents electronically prior to printing. The major : benefit will be lower costs of producing quality layouts, thus making it possible for : printers to accept shorter-run jobs.

: dards. This will lead the way to globalizing the printing and publishing industries. :

*

eliminate several of the intermediate steps currently used in preparing printing - plates.

Improved telecommunications and the introduction of digital data exchange stan-

Development of direct-to-plate and direct-to-press technologies. Such changes will

PRESS OPERATIONS Automation of press operation. Use of waterless lithographic plates that do not require a dampening system. Use of non-alcohol fountain solutions and low-VOC press cleaners. Use of low- or no-VOC inks such as soy- and water-based inks, high-solids inks,

ultraviolet and electron-beam curable ink, and chemically reactive inks. Recycling of waste ink. Growth in plateless printing technology market.

- Numbers in parenthesis refer to specific references lied in Appendix 1 beginning on page 53.

6

POSTPRESS Automation of post-press operations. Use of in-line finishing. Use of water-based adhesives.

These technology trends indicate the direction that the printing industry is moving. The message to the small printer is that efforts should be made to use cleaner and more efficient equipment. However, due to the small size (and lack of capital) of many printing facilities, major changes often cannot be implemented immediately or in some cases not at all. Fortu- nately, there are also many simple measures to effectively reduce waste and improve printing efficiency. These simple measures are usually not capital intensive and can be implemented relatively easily. Both major process changes and simple measures will be addressed in this manual.

7

! 111. Waste Reduction Incentives For The Printing Industry

m

9

I I I. Waste Reduction Incentives For The Printing Industry

In the past, waste resulting from industrial processes was accepted as an inevitable part of doing business. This view is beginning to be challenged as government regulation and public environmental awareness increases. Now, businesses are beginning to see waste as a reflection of production inefficiency. A company producing large quantities of waste, which could be avoided, is not operating at peak efficiency. There are many incentives for a printer to adopt waste reduction as an integral part of doing business. These incentives can be grouped as follows:

A. Tangible Direct Cost Savings There are a number of direct costs associated with waste generation that are often

overlooked in decision-making. These expenses, which collectively can significantly affect the cost of doing business, relate to the following:

Commitment of time by plant personnel to study, understand, and meet

Administrative time associated with record keeping and reporting as required by law. Time for interaction with regulatory agency inspectors. Time and money required for waste stream sampling and testing. Time required to generate and update a hazardous waste reduction plan. Costs associated with permitting for planned releases. Costs associated with the replacement of raw material lost as waste. Labor costs associated with handling waste in the plant. Waste transportation and disposal costs.

environmental regulations.

B. Intangible Cost Savings and Other Incentives Printers can also find incentive to reduce waste by considering some intangible costs

related to waste generation. These costs are difficult to quantify because they are only potential costs, but if one or more of these are realized, the effect on a business could be catastrophic. Examples of theses costs are those related to:

Poor worker safety Risk of worker health lawsuits Future financial liability associated with improper waste handling, treatment, or

Poor worker loyalty Bad public image

disposal (by generators, transporters, or treatment and disposal facilities)

11

Ill. WASTE REDUCTION INC- FOR THE PRINTING INDUSTRY

C. Improved Efficiency and Competitiveness By the end of the 1970's and into the early 1980's' many American companies began

: to undergo a "quality revolution." A shift in values from producing "quantity" to producing * "quality" began to take shape. The companies leading this charge see waste as misplaced . resources. Reducing or eliminating these lost resources lowers the cost of doing business and : provides a competitive advantage. Many large companies have already developed business * philosophies in which pollution prevention is an integral part. In many cases, they employ a staff of engineers with waste management responsibilities and have employee committees to

1 solve in-plant waste problems.

* employ a staff of experts or to implement major process changes which require installing the most efficient equipment on the market. However, the lessons learned from large companies

: can be applied on a smaller scale to these facilities. Changes are likely to be less glamorous in small facilities, but no less important.

Printing companies are typically small and generally do not have the resources to

Small companies can receive technical support at no cost from state agencies, universi- : ties, and from chemical and equipment suppliers. Many of these "public agencies" and manu- : facturers are continuously researching and developing more efficient products and processes.

Therefore, a good relationship should be developed between printers and their "no-cost consult- - ants." Two sources of assistance in Tennessee are the Small Business Program (page 74) and : the University of Tennessee's Center for Industrial Services (page 74).

12

IV. Regulations Potentially Affecting Printers Waste Management Strategies

13

IV. Regulations Potentially Affecting Printers Waste Management Strategies

The following regulatory information affecting printers is summarized from a draft report prepared by the EPA's Economics and Technology Division Office of Pollution Prevention and Toxics (2)

A. Resource Conservation and Recovery Act (RCRA) In a climate of constantly changing regulations and new waste management philoso-

phies, it is often difficult for the small printer to keep track of required waste management and disposal practices. Printers may be subject to different solid and hazardous waste regulations under RCRA depending on the amount of waste produced. Appendix I1 (page 57) is provided to assist your company in determining its regulatory status. Title 40 of the Code of Federal Regula- tions (CFR), Subchapter I-Solid Waste, Parts 240 - 281 outlines the specific requirements that a waste generator must consider. Depending on a company's generator status, it may or may not be subject to all of these requirements. A summary listing of the CFR Parts relating to hazardous waste is included in Appendix I11 (page 59).

A summary of the federal requirements for generators of hazardous waste is available in the 1990 edition of the EPA's RCRA Orientation Manual. Copies of this document are available from the Government Printing Office (Superintendent of Documents Washington, DC 20402. (202) 783-3238). The state EPA offices are responsible for administrating the federal programs. In some cases, they may have more stringent requirements. Information on Tennessee regulations may be obtained from the Tennessee Division of Solid Waste Management (see Appendix IV (page 61) for phone numbers)

hazardous waste listings. Appendix V (page 63) has the current RCRA listed solvents and the new solvents which may soon be added to the list.

A list of solvents is currently being reviewed by the EPA which may be added to the

B. Clean Air Act (CAA) The Clean Air Act Amendments of 1990 (CAA) strengthen existing Federal regulations

and contain new requirements for sources of air pollution which impact a number of small businesses. Printers are primarily associated with volatile organic compound (VOC) emissions. Primary sources for these emissions are fountain solutions, inks, and cleanup solvents. Appendix VI (page 65) includes a listing of the materials which may cause VOC problems for the printer.

The CAA mandated that each state establish a Small Business Assistance Program.

. '

15

@ N. REGUIATIONS POTEMlwY AFFECTING PRWIZRS WASTE MANAGEMENT STRATEGIES

Each program is to have an Ombudsman (Advocate) to advise the small business on CAA matters, a technical assistance program to help small business comply with CAA requirements and a Compliance Advisory Panel to monitor and evaluate the overall effectiveness of the state program. Services are provided at no cost. Tennessee Program Assistance can be obtained by calling 1-800-734-361 9.

OTHER IMPORTANT ISSUES UNDER THE CLEAN AIR ACT AMENDMENTS OF 1990 A Control Technology Guideline (CG) for lithographic printing has been developed

Printers not subject to a CG but that are k a j o r sources" may be subject to RACT

State or local permits are required for certain activities such as: Constructing or operating new or existing presses, coaters, control devices, boilers,

cyclones, evaporators, distillation units, and some proofing and bindery equipment.

Modifying existing equipment or to change process materials (e.g. inks, fountain solutions, coatings, cleaning solvents, and other chemistries).

bythe EPA.

(Reasonably Available Control Technology).

C. Clean Water Act (CWA) Most printers do not have significant wastewater problems. Usually all effluent is dis-

charged to the Publicly Owned Treatment Works (POW). An agreement must be reached between your company and the P O W before the discharge is accepted. The agreement will be partially based on constituent concentrations such as Chemical Oxygen Demand (COD), Bio- chemical Oxygen Demand (BOD), and heavy metals (e.g. silver, cadmium, chromium, lead). The discharge may also be required to meet restrictions of the local sewer authority which may be separate from those of the P O W . If printers are unable to meet discharge standards, they will be required to pretreat wastewater before discharge.

If a facility discharges wastewater directly to a body of water, such as a nearby stream or river, it must have a permit which specifies the allowable pollutant levels and discharge flowrates. If standards cannot be met, the printer may be required to purchase and utilize an in-house wastewater pretreatment system. Sometimes, permits require a facility to monitor con- taminant levels in the discharge and the receiving body of water.

The specific requirements of the CWA can be found in 40 CFR, Subchapter D- Water Programs and 40 CFR Subchapter N- Effluent Guideline and Standards. A list of the major sections under each subpart is included in Appendix I11 (page 59).

16

V. The Lithographic Printing Process And Waste Generation

17

: v. The Lithographic Printing Process and Associated Waste Generation

A. Background Lithography, or offset printing, is the most common form of printing. It is expected to

Sheet-fed lithography is the printing of images onto individual sheets of paper or other * grow through the 1990's and stabilize to almost 50% of all printing operations.

: substrates. It is commonly used for printing books, posters, greeting cards, labels, packaging, advertising fliers and brochures, periodicals, and for reproducing artwork. Web-offset lithogra-

- phy uses a continuous roll of paper onto which images are printed. Web printing is commonly . used for large volume jobs including the printing of periodicals, newspapers, advertising, books, : catalogs, and business forms.

B. Overview of Lithographic Printing Operations associated with lithographic printing include image processing, plate

- making, printing, and finishing. Other suboperations include proofing, makeready, ink drying, . and press cleaning. Smaller companies may contract with outside vendors to perform the : image processing and finishing operations. A flowsheet of the typical operations performed in

. : a lithographic printing facility is shown in Figure 1 (page 20). During lithographic printing, images are transferred from a thin metal sheet or paper

. plate to a soft rubber roller and then onto the substrate. The image area and the non-image

- Image areas repel water while attracting the printing inks. Conversely, the non-image areas . attract water and repel inks. Plates are mounted on rotating cylinders which contact several : porous rollers that wet the plate with the fountain solution (typically water and alcohol) and ink. e The ink wets the image areas and is prevented from bleeding into the non-image areas by

fountain solution. Some adjustment of chemicals in the fountain solution is usually needed to . produce a good print quality. For a detailed process description useful in training inexperienced

employees see Appendix VI1 (p. 67).

area of the plates lie in the same plane and are separated only by their chemical composition.

19

V. THE LlTHoGRAPHlC PRINTING PROCESS AND AssoclATED WASTE GENERATION

Figure 1. Lithographic Printing Process Flow Diagram

Art Work, Computer Image, or Copy

1 Exposed and Waste Fdm

Empty Chemical Containers

Spent Processing Chemicals and Wastewater

Waste Proofs

Damaged or Unusable Plates

Paper Plates Empty Chemical Containers

Plate Processing Spent Processing Chemicals

Aluminum or

Chemicals and Wastewater

Waste Paper

VOC Air Emissions Fountain Solution

Ink paper

Fountain Solution Cleaning Solvents

Rags or Paper Wipes

Empty Ink Containers Unacceptable prints VOC Air Emissions Waste I Ink Solvent Soiled Rags and Paper Wipes Unusable Plates Spent Fountain Solutions Used or Damaged Blankets Spent Equipment Oil

Paper Scrap

Glue I Adhesive Waste Glue I Adhesives -

+ Finished Product

20

V THE LITHOGRAPHIC PRINTING PROCESS AND AssoclATED WA!?X GENERATION

C. Common Waste Disposal Practices for Lithographers Each operation in the printing process is characterized by a number of recurring waste

: streams with which the printer must contend. As stated previously, acceptable waste disposal practices will vary for different facilities and depend on the types and quantities of waste generated. Each facility should determine how to comply with the current federal and state regula-

: tions. Table 1 lists waste streams commonly encountered and the typical methods used for : disposal.

Table 1. Waste Streams and Disposal Practices for Lithographic Printing

UNIT OPERATION

IMAGE PROCESSING

PROOFING

PLATE-MAKING

21

WASTE STREAM Exposed unusable film

Empty photoprocessing chemical containers

Wastewater [(containing developers, fmers (with silver), rinse waters, reducers and intensifiers)]

Waste film and paper

~~~~~~ ~

Empty plate developing chemical containers

Wastewater (containing acids, alkali, solvents, plate coatings, developers, and rinse waters)

Damage plates

rYPICAL DISPOSAL PRACTICES*

Discarded with municipal waste May be recycled for its silver

Discarded with municipal waste

content

or recycled ~

Discharged to the Publicly Owned Treatment Works (P0-w

(May require pretreatment prior to discharge)

Fucing solutions may be recycled for their silver content

Discarded with municipal waste Film may be recycled for its

silver content

Discarded with municipal waste or recycled

Acids and alkali may be drummed for disposal

Discharged to the POW (May require pretreatment prior

Some solutions may be recycled

Discarded with municipal waste Aluminum plates may be

to discharge

for their silver content

recycled

V. THE IJIHOGRAPHIC P R " G PROCESS AND AssoclATED WASTE GENEFLATION

Table 1. Waste Streams and Disposal Practices for Lithographic Printing continued

UNIT OPERATION WASTESTREAM IYPICAL DISPOSAL PRACTICES' Empty ink containers Discarded with municipal waste

Bulk containers are refilled by or recycled

the SUDDlier

MAKEREADYAND PRINTING

Discarded with municipal waste Used or damaged blankets Used plates Discarded with municipal waste

Aluminum plates may be recycled

_ _ _ _ _ _ _ ~

Off-specification prints Discarded with municipal waste

Discharged to the PO'W (May require pretreatment prior

or recycled

to discharge)

Spent fountain solutions (May contain chromium)

~ ~~ ~

Waste ink and solvent mixture from equipment cleaning

Commonly discarded with municipal waste by small companies after dying

May require disposal as hazardous waste

~~ ~~

Soiled cloth cleaning rags May be laundered on- or off-site May require disposal as hazard

ous waste otherwise discarded with municipal waste

May require disposal as hazard ous waste otherwise discarded with municiDal waste

Soiled paper wipes

~

Spent solvent (removed from wipes before disposal)

Shipped off-site for use in a fuels program or recycled on- or off -site

Vented to atmosphere May require control

(destruction or capture before release)

VOC air emissions (evaporated solvent from inks, isopropyl alcohol from fountain solutions, and cleaning solvents)

*aP paper WISHING Recycled or discarded with municipal waste

Waste glue, adhesives, and lacquer

Shipped off-site for use in a fuels program or recycled on- or off-site

. These methods may or may not be in compliance with regulations applicable to your facility. You are responsible for evaluating - your waste strpams to determine their regulatory status.

22

! VI. Waste Reduction and Recycling Opportunities For Lithographic Printers

23

: VI. Waste Reduction And Recycling Opportunities For Lithographic Printers

A. Introduction It is widely accepted that wherever possible, practices and procedures should be

- adopted that reduce, avoid, or eliminate waste at its source. When source reduction is not : possible, recycling and reuse are the next best options. Some basic approaches to pollution : prevention are:

Improve housekeeping, maintenance, training, and inventory control. Change raw materials to less hazardous substances. Improve operating procedures. Replace or modify production equipment for optimal performance. Recycle potential waste in-process or on-site. Redesign or reformulate products.

In many cases pollution prevention is economically attractive because resources are * used more efficiently and problems associated with waste generation are reduced or avoided.

Payback periods vary depending on the cost of equipment needed to achieve the reductions.

: intangible costs listed above (see Section 111, page 9) may be avoided. Sometimes a measure is attractive, but requires changing operating procedures. These measures are often resisted by

. employees. I The best pollution prevention strategies can often be identified by managers or press-

- room employees intimate with the operations. However, preventing waste has not been a major priority of industry. Rather, waste is typically an afterthought. Simply by changing this

: focus and asking new questions, instead of doing business as usual, will give a new perspective to old problems and provide new and abundant solutions. Plant management should encourage all employees to be active in searching for new and better ways to do things. This process

Sometimes it is difficult to see the direct benefits of reducing waste, but the risk of

. can begin by asking "Why is waste produced in a given process step and how can it be pre- : vented?" instead of "What can I do with waste once it is generated?*

Some effective methods to get employees involved with pollution prevention include: Rewriting job descriptions emphasizing waste reduction as an important part of their

duties. Instituting an employee incentive program. Employees should be rewarded for good :

ideas that lead to better plant operation. Incentives can be monetary, certificates *

or plaques, or written acknowledgment posted in the facility. :

preparedness, and compliance with regulations. Training employees in pollution prevention along with health and safety, emergency

25

VI. WASTE REDUCTION AND RECYCLING o~p0RTuNrnEs FOR LIMOGRAPHIC m

Some ideas to get your pollution prevention program going are presented below. For hands-on expert assistance, or for more information on a specific measure, contact the Univer-

* sity of Tennessee's Center for Industrial Services Waste Reduction Assistance Program (refer to . Appendix VIII, page 73).

B. Waste Reduction Through Inventory Control

1. Inventories should be managed on a "first-in", "first out" basis Keeping track of materials is an ongoing problem for many companies. It is easy for a

* can of ink to get pushed to the back of a shelf and forgotten. Software is available to computer- - ize inventoy control so the amounts and ages of raw materials can be tracked. More impor- : tantly, an employee must be given the responsibility to use raw materials in a timely fashion to : reduce the quantity of outdated material.

2. Materials having an expired shelf life should not be automatically

Expired lots should be tested for effectiveness. This may require lab work, test runs, or thrown out

. simply a visual inspection. Rather than becoming a waste, the material may be usable. If an expired ink looks good and prints well, it is probably good. Also, waste material that is not

* usable may be recyclable. A recycling outlet should be found for out-of-date raw materials that - are no longer wanted (see Appendix IX, page 77).

3. Materials should be inspected when received and off-specification or damaged materials returned immediately to the manufacturer or supplier

Without pre-inspection, "bad" materials are not discovered until they are used during production. At that point it may be too late to send the material back to the manufacturer and waste (for example bad prints) may have been produced in the process.

4. Order raw materials as needed Small printers should generally order ink in small containers as needed in production.

This will prevent large quantities of material from expiring before they am used. Before disposing or recycling of containers, they should be cleaned to maximize material use and to prevent potentially hazardous materials from entering the waste stream.

5. Store inks properly to prevent skinning and drying All ink containers should be resealed immediately after use. Ink in open containers can

become contaminated with paper dust and dirt and a "skin" can form on the surface, which eventually hardens and becomes a waste. The next best option, after replacing lids in a timely fashion, is to use a commercially available anti-skinning sprays. These sprays can be

26

. applied to the ink surface to form a protective layer which prevents evaporation of ink solvents : and subsequently prevents skinning. Contact your ink supplier for a product recommendation.

. :

6. Order materials in bulk containers whenever possible A common practice for many large printers is to scrape ink containers clean and then

* discard them in the trash. Purchasing inks in bulk containers, which can be retumed to the . supplier for refilling, will reduce the amount of solid waste generated and cut down on the time

required for cleaning the container before disposal. If retumable containers are not available : from suppliers, it may still be possible to reduce disposal of empties by sending them to con- - tainer recyclers or reconditioners.

sourceS for more infomation: References $ 4

C. Waste Reduction Measures for Image Processing

OPPORTUNITIES FOR RECYCLING USED FILM AND PAPER Exposed and expired film is generated during photoprocessing and proofing opera-

: tions. After a job is complete, the film and proofs associated with the job are usually discarded. : Occasionally, incorrectly stored film may become waste.

:

1. Recycle unusable photographic film and paper Exposed and spoiled photographic film and paper is commonly sold or given to

: reclaimers by much of the printing industry with the exception of very small companies and * those companies located in areas not served by silver reclaimers. Recyclers that purchase - discarded film can usually be located under "Gold and Silver Refiners and Dealers" in a busi- : ness telephone directory. Large companies that generate significant quantities of waste film and :

paper will realize a revenue from the sale these materials to recyclers. Often it is advantageous for companies to sort the film into "mostly blsck" versus

- "mostly clear" sheets. The more black showing, the higher the silver content. Recycling compa- - . nies typically pay double what they pay for mostly clear sheets. b- For very small companies it may not be profitable :

: for the recycling company to pick up a small amount of waste film. Small printers may consider : * storing waste film, if space is available, until a sufficient quantity is accumulated and then call a -

recycler to make a pick- up. A cooperative arrangement between small printers in a region may : be a viable option for a recycling program. A group of small printers would potentially generate :

enough film to make it attractive for a recycler to provide its services. Your regional Printers Association (see Appendix VIII, page 73) can provide a member listing. In some areas there are :

- no recyclers nearby and thus, waste film must be landfilled.

27

VI. WASTE REDUC~ON AND RECYCUNG o m m u r " FOR UTHOGRAPHIC P-

OPPORTU"~ TO'REDUCE THE TOXICITY AND QUANTITY OF WASTEWATER EFFLUENT Silver halide films are the most common types used. The major draw-back of these

films is that waste processing solution (particularly fucer baths) may be hazardous due to its silver, and other dissolved metals, concentrations. Some sanitation districts will accept photo-

: processing wastewater with a low silver concentration (you will need to have an analysis per- : formed and then contact your POW). However, some wastewaters may require pretreatment * to remove silver before discharge. Typical tmatments to remove silver are electrolyte deposition . and metallic replacement. Consult your local P O W for information on wastewater discharges.

1. Use silver-free film as a substitute for silver halide film Using alternatives to silver-based film will eliminate the problem of locating a recycler

. for waste film and any wastewater pretreatment requirements. Two successful alternatives are : diazo and vesicular films. Diazo compounds are commonly used as coatings for presensitized

and wipe-on plates. Vesicular films have a honeycomb-like cross-section and are coated with a thermoplastic resin and a light-sensitive diazonium salt. Check with your film supplier for addi-

: tional information. Several suppliers are l i e d in Appendix IX (page 77). Other films that are beginning to see greater use are photopolymer and electrostatic

- films. Photopolymer films contain carbon black as a substitute for silver and are developed in a . weak basic solution which needs neutralizing before disposal. Treated effluent is generally not : hazardous. Electrostatic films are high-resolution, non-silvered substrates that can be developed

at a rate comparable to silver films. An electrostatic charge makes the film light- sensitive, and a - toner brings out the image after the film is exposed to light.

C a w The major drawback to using diazo and vesicular films is that they develop slower than silver halide films. Thus, production scheduling may have

Use of photopolymer and electrostatic films may require the purchase of new develop- * to compensate for the lengthened development time.

: ing equipment. Therefore, project financing may be a major limiting factor for small printers. * Also, since the technologies are not widely used, their costs are likely to be higher than that of * standard film.

Sou~es for more information: Reference 3

2. Use "squeegees" to wipe off excess liquid from film and paper in non- automated or tray developing operations

This measure prevents chemical carryover between process baths. Chemical carryover - can typically be reduced by at least 50%. It is well-suited for the very small printer or any

: company still using a "tray" photoprocessing operation. By effectively limiting contamination : carryover, the life of a bath may be substantially increased. In addition, its recyclability is increased, and the amount of replenished chemicals required for make-up is reduced. Contami- . nant concentration of rinse water is also reduced.

'

28

Vi. WASTE REDUCTION AND RECYCLING OPPORTUNITIES FOR LITHOGRAPHIC PRINlZRs

5- Film images may be damaged if they are used before the emulsion has had time to harden. Therefore, employees must be adequately trained for proper handling.

Sources for more infomation: RefeEnca 3,s 6

3. Extend the fixer bath life In both an automatic developer and in a "tray" operation, the development process is

stopped by immersing film in a fixer solution. The chemistry of this bath causes small amounts of silver complexes to solubilize. When the solution silver concentration reaches a critical level, insoluble compounds, which impair the image quality, begin to form in the photographic emulsion. These compounds cannot be removed practically after their formation. Thus, the fixer bath must be replaced before this critical concentration of silver is reached. The following simple measures will effectively increase the fixer bath life:

bath preceding the fixer bath is slightly basic. Developer solution adhering to the film gradually raises the pH of the fixer bath from an optimum of 4.1. At a pH of approximately 5.5, the potassium alum, which prevents swelling of the emulsion, is less effective and the bath must be replaced or the pH lowered by adding acetic acid.

Add ammonium thiosulfate (Hypo) which can double the allowable concentration of silver build-up in the bath. When Hypo is used in the fucing bath, insoluble compounds in the photographic emulsion do not begin to form until the silver concentration is approximately twice that when Hypo is not used.

developer solution will cause pH problems in the fixer bath. To prevent this from occurring, a "stop" bath can be installed between the tank to wash the developer solution from the film and to provide neutralization. i- Printers must be careful when altering the chem-

istry of photoprocessing baths. Unless the staff has considerable experience with photoprocessing chemistry, this measure is not recommended. Implementing this measure should reduce the frequency the fixer bath must replaced, but it may create a higher concentration of silver released to the sewer in the wastewater. Since the fixer bath's silver concentration will be approximately twice as high as it was previously, more silver is carried out of the bath and into the rinsewater. This could create problems with the sewer authority. It may be advisable to try a trial operation and analyze a "would be" wastewater sample before using extended-life baths.

Add acetic acid to the fucing bath as needed to maintain a low pH. The developer

Use an acid stop bath prior to the fucing bath. As mentioned above, drag-in of

Sources for more information: References 1, 6

29

VI. WASTE FEDWITON AND RECYCLING o m m u “ FOR LITHOGRAPHIC PRINTERS

4. Use counter-current rinsing in the photo-processing operation Process solution contamination and rinsewater usage can be reduced by using counter-

- current rinsing instead of parallel tank wash systems. In a parallel system, fresh water enters each wash tank and effluent is collected and piped to the sewer. In counter-current rinsing, the

: water from previous rinsings is used in the initial film washing stage. Fresh water enters the process at the final rinse stage, instead of at each wash tank. Much of the contamination is

. washed off of the film before it reaches the final rinse.

* current rinsing system (CCRS) require more space. Installing a CCRS may require retrofitting . existing equipment which can be difficult and expensive. Check with developing system vendors : for more information. See vendor list in Appendix IX (page 77).

r Co-- Generally photoprocessors using a counter-

S~urces for more information: Refemnces I , 5,6, 7

5. Recover silver from wastewater Wastewaters from photoprocessing operations, especially from fAng baths, contain

e

dissolved silver. Depending on local sewer authority policy, printers may or may not be required . to pretreat this water to remove silver before discharge to the POW. A viable option for many

printers is on- or off-site recovery of silver for sale to a metal recycler. Economical methods to : recover silver include electrolyte deposition and metallic replacement.

. recovery unit, a direct current low voltage is produced between a carbon anode and a stainless : steel cathode. Metallic silver deposits on the cathode. Once silver is removed, the fAng bath

may be reused by mixing it with fresh solution. To maximize the efficiency of silver recovery and . photodeveloping, there are several important issues to consider:

streams to increase electrolytic efficiency. This can be accomplished by replenishing fwer at a * higher than normal rate during film processing.

: series. The second cartridge would serve to reduce silver breakthrough. Installing a cartridge to polish the effluent of an electrolytic unit would significantly reduce silver levels in discharges to

- the sewer. The efficiency of an electrolytic silver recovery unit can be significantly increased by

: adjusting the concentration of sulfite in the silver-bearing wastewater to 10 to 25 gramditer and * the pH to 7.8. This will also serve to reduce sulfiding.

Using a low current for the first plating of silver in an electrolytic unit will reduce : silver fin formation (“finning”). This condition limits the recoverable silver from a batch of * process waste.

Uectroyte deposition is the most commonly employed method. In an electrolytic

Concentrations of silver and iron should be kept as low as possible in the waste

Silver recovery may be enhanced by using two chemical recovey cartridges in

In metdhc repi’acement, the spent bath solution is pumped into a cartridge containing steel wool where an oxidation-reduction reaction occurs. The iron in the wool is replaced by

30

VI. WASTE REDUCTION AND RECYCLING 0PPORlU"ES FOR LITHOGRAPHIC PRINTERS

silver through the oxidation-reduction reaction, and the iron settles to the bottom of the cartridge *

: as sludge. The entire cartridge can then be sold to a recycler. : - "Gold and Silver Refiners and Dealers" in a business telephone directory. Recovered silver is

: worth about 80% of its current commodity price (see local newspaper or the Wall Street Jour- . : nal). Fiom effluent analyses a facility can predict the amount of silver that can be recovered and : - revenue generated.

: quantities of aqueous silver to make recovery profitable. However, it is likely that such facilities

Some companies that buy cartridges containing recovered silver can be located under

a- Small companies may not generate sufficient :

will not have problems with discharging their wastewater to the P O W . Sources for more information: Refemnces I , 5, 63Q3.I

OPPORTUNITIES FOR PREP- OPERATIONS PROCESS CHANGE As stated previously, image making and photoprocessing produce waste film and

wastewater. Traditionally, page layouts have been developed through a trial-and-error process : where images and text are manually "pasted" to a page. The layouts are photographed and : checked. If corrections are needed the process is repeated. When the final layout is complete, * a proof is made for customer review. If the customer wants changes then the process is : repeated. Each iteration generates additional waste film and wastewater.

- : *

1. Replace the current image-making operation with a "computerized electronic prepress system" for type-setting and copy preparation

In these systems, an operator produces a page layout by using a computer to combine - text, photos, and graphics. The layout can then be edited on a monitor rather than on paper. . Proofing can also be done on the monitor. Only the final version is developed, thus eliminating : waste film and processing wastewaters. New products that are available for computerized * prepress operations include:

Graphic-oriented Workstations: Front-end platforms (FEP) are evolving from iow- : cost personal computers to graphics-oriented work stations running production-level software. : The software will be based on products originally developed for CAD/CAM applications.

Color Electronic Repress System (CEPS): Complete color and B&W page makeup . including color balancing and correction can be performed with CEPS. It will be possible to : network CEPS with other digital equipment including modems for telecommunications and to * direct-drive platemaking systems.

Flat-bed scanners: These systems use Charge-Coupled Device (CCD) technology as : the primary imaging element. Flat-bed scanners are capable of scanning a page at a time and : can be used in both color and B&W work. These systems can be used with personal computers,

graphic work stations, or CEPS.

31

VI. WASTE RuxlcnONAND RECYCLING 0PpoRTU"Es FOR LmtOGRAPHlC PRNTERS

- Currently, the initial cost of these systems is high and may prohibit small companies from using electronic prepress equipment. However, the

: price of the necessary hardware and software is dropping as systems become more available - and should be affordable to small and medium sized print shops in the next few years. Sources for more information: Refer" I , 8, 9

OPPORTUNITIES FOR IMPROVED PHOTOPROCESSING CHEMICALS STORAGE AND HANDLING Many photoprocessing chemicals and film are light-sensitive and air exposure will

: cause a detrimental oxidation reaction. Some shops have been shown to waste one-fourth of : their photosensitive film and paper due to improper storage and handling.

1. Always follow the recommended storage conditions for photoprocessing

Manufacturers provide instructions which outline the best methods for storing their chemicals and film to increase shelf life

: products. It is sometimes more convenient to store materials in a manner not recommended by * the supplier. The importance of proper storage should be emphasized to employees.

Sources for more information: Refenmces 23

2. Use glass marbles to bring liquid levels in containers of process chemicals to the brim each time they are used

Since many commonly-used photoprocessing chemicals will oxidize in air, it is benefi- : cial to minimize the airhquid interfacial area. By adding glass marbles to a partially-full con- * tainer, the liquid level rises into the container neck where the cross-sectional area is a minimum. This will extend the life of oxidizable chemicals by minimizing the area for oxygen contact. This will result in a modest reduction of the chemicals that "go bad" and that need replacing.

Sources for more information: Refernces 3, 4

D. Waste Reduction Measures for the Platemaking Process

OPPORTUNITIES FOR RECYCLING ALUMINUM PIATES Following a printing job, used plates are disposed of unless there is a possibility that - they wilt be needed in the future.

1. Sell used and damaged plates to an aluminum recycler It is common practice for printers to sell their scrap aluminum plates to metal recyclers.

- Companies that buy scrap aluminum can be located under "Scrap Metals" in a business tele- . phone directory.

32

VI. WASTE REDUCTION AND RECYCLING OPPORTUNmES FOR UTHOGRAPHIC PRlNTEFS

OPPORTUNITIES TO REDUCE PLATEMAKING WASTEWATER VOLUME Conventional platemaking developers can produce polymer effluents that may contain

contaminants which cause disposal problems. Some of these solutions may require in-plant treatment prior to discharge to the POW.

1. Use laser plate-making with an electronic imaging system With this type of systep, text and photos are scanned into a computer and edited on a

monitor as described above. Instead of printing the final copy, non-silvered plates are made directly from the computer image using a laser beam. This reduces the quantity of film, develop ing chemicals, and paper. Electronic imaging systems can reduce most of the waste associated with prepress and platemaking operations.

print shops due to high equipment cost. However, the needed computer hardware and software prices are dropping steadily and they likely will become more affordable for smaller printers . - in the future.

.

*

&- These systems are currently impractical for small

Sources for more information: Refennces 1,3, 4,

2. Use presensitized plates that are processed with water These plates are water-resistant until exposed to light. Upon exposure, the coating in

the non-image area becomes water-soluble. Developers for aqueous plates contain about 50% to 95% water with the remainder being alcohol or other solvents. Thus, solvent use is greatly reduced. Aqueous plates are quite durable, and converting from solvent-based plates is easy.

Since less chemicals are used in the developers, they are generally less expensive. Contact plate suppliers for more information (See Appendix IX, page 77).

Sources for mom information: Refennces 3, 4,5, 10

.

E. Waste Reduction Measures for the Printing Process

OPPORTUNITIES FOR WASTE REDUCTION THROUGH PRESS MODIFICATIONS Pres operations produce a number of waste streams including: scrap paper, waste ink

. : : and solvent, VOC air emissions, and solvent-soaked rags or paper wipes. Equipment is avail-

able to increase press efficiency and reduce waste generation. Contact press equipment suppli- . ers for more information on the following options:

1. Install web break detectors There is a commercially available non-contact electronic system which detects web

. breaks without smearing or creasing the web. If tears are not detected, the broken web begins : to wrap around the rollers and forces them out of their bearings. These systems automatically

.

33

VI. WASTE REDUCTION AND RECYCLING OPPoRNNmES FOR LlTHOGRApHlC PRNlER!3

shut down the press when a break is detected. Although web break detectors are normally used to avoid severe press damage, they also reduce paper and ink wastes.

2. Use automatic web splicers The splice can be made while the paper is running at operating speeds or while the

paper is stationary. Either method can yield in significant savings in time and paper waste reduction.

3. Use automatic ink levelers Ink waste and contamination around the press can be prevented and optimum inking

conditions can be maintained by installing an automatic ink leveler in the fountain.

4. Install an automatic press adjustment system An automatic press adjustment system can speed up the makeready step and save

paper and ink. Examples of these systems are automatic plate benders, automated plate scanners, automated ink density setting systems, computerized registration, and inldwater ratio sensors.

Automatic plate benders are designed to prevent problems associated with fitting a plate to cylinder such as: plate cracking, nowstraight plate bending along the bend length, curvature of the plate differing from that of the cylinder, and other plate fitting problems that affect proper registration. Automated plate scanners have been developed for both web and sheet- fed offset presses that take advantage of microprocessor technology and high quality optics. Finished plates are scanned to determine the relative density of the printing image across the plate's surface. This information is then used to set the ink fountain keys. Automatic ink- key setting is usually part of a system that includes scanning densiometry to determine ink density. Information about the ink density is then transmitted to a computer-controlled inking system so that automatic adjustments are made to the ink profile for each ink slide position. Automated registration uses optical scanners and microprocessors to lock onto the marks for the entire press run. InWwater sensors inform press operators whether ink flow or water flow needs adjusting to result in the optimal inWwater ratio.

sourceS for more information on p m moiiificafion: References 3,4,5

OPPORTUNITIES FOR ALTERNATIVE INK USE Traditional lithographic inks are formulated with petroleum-based oils and metal-based

pigments. Oil is useful to impart flow characteristics and the metal pigments contribute to brilliant colors. Recently, hazardous metallic pigments have been eliminated from most lithographic inks. However, there is growing concem over petroleum-based inks because they emit VOCs while drying. Several substitutes for the petroleum-based inks an? now available.

34

VI. WASTE REDUCTION AND RECYCLING o m m u " FOR UTHOCRAPHIC PFUNTEFS

1. Use UV-curable inks These i n k consist of one or more monomers and a photosynthesizer that selectively

absorb ultraviolet (UV) energy. UV inks do not contain solvents and cure when exposed to ultraviolet light. The UV inks can remain in the ink fountains (and on plates) for longer periods of time between printing runs, thus reducing clean-up frequency. Some reported advantages of UV curables include:

Decreased or eliminated VOC emissions Less frequent press cleaning and associated solvent use Reduction in required floor space (eliminates need for dying ovens or racks) Increased throughput Reduced health and safety hazards associated with solvents Elimination of corn starch used to protect ink from smearing onto the backs of other

i- On the negative side, the following barriers have

In many cases performance is not as good (insufficient opacity and color matching) UV inks cost 75 to 100% more than traditional inks

* Outdoor durability may be a problem UV inks may cdntain toxic materials which can hamper paper recycling Worker safety issues (exposure to UV light and certain chemicals in the inks) The capital investment is high for conversion to UV systems Small printers may not experience increased production speed and ink d c o v e r a g e

Sources for more infomation: Refen" 3, S, 11, 12,s

printed sheets

been reported by lithographic printers using UV curables:

benefits due to shorter average runs

2. Use SoyNegetable Oil-Based Inks Inks made with soybean or other vegetable oils are proving to be a viable substitute for

- petroleum-based ink. These inks set by oxidation. Soybean and vegetable oils have a low : volatility, therefore, they are not considered VOC's. Possible advantages to these alternative : inks include:

Reduced VOC emissions More "forgiving" on older equipment Increased ink coverage Easier to balance ink and water Safer and faster press clean-up Compatible with recycled paper

35

VI. WASTE REDUCTION AND RECYCLUVG 0pPOKN"ES FOR UIHOGRAPHIC

s- There are also some disadvantages to soy and

100% soy or vegetable inks dry slowly Soy inks are currently more expensive than petroleum-based inks Soy inks do not provide a disposal advantage over petroleum-based inks

Sources for more information: Refezences 3, 7,s 11,10, 1314

vegetable oil-based inks.

OPPORTUNITIES FOR REDUCING PRESS CLEAN-UP WASTE Solvents are commonly used for press cleaning and press side clean-up of screens.

. Some solvents used include: mineral spirits, methyl ethyl ketone (MEK), acetone, butyl solusol, : cyclohexane, toluene, and methyl isobutyl ketone (MIK). These substances are a significant : sou= of VOC emissions. Equipment cleaning also generates solvent-contaminated rags and/or - paper wipes. All types of wipes are considered hazardous waste if they are disposed of wet with

solvent. Currently, if rags are laundered on- or off-site they may not be considered hazardous : waste and may not be subject to RCRA Subtitle C regulations. However, the practice of launder- : ing solvent-soaked rags may cause future problems for laundering facilities due to changing

effluent restrictions. The best management practice is to reduce the solvent content in the rags . and the number of waste rags.

1. Segregate and reuse cleaning solvent The waste solvenvink mixture that drains from, or is "cut off", rollers with a blade and

: collected in a pan should be segregated by ink color. The collected solvent can be reused for : future roller cleaning for the same color ink. Reusing solvent will reduce the quantities of fresh * solvent used for final cleaning. In some cases the spent solvents can be used to thin inks of the . same color.

Sources for more information: Refezence 3

2. Use automatic cleaning equipment This equipment increases the efficiency of the cleaning solvent. An automatic blanket

: cleaner consists of a control box, a solvent-metering box for each print unit, and a cloth rag - handling unit. These units increase press efficiency in many cases. The increased speed of . automated washing compared with manual cleaning results in fewer wasted impressions during : the shorter period needed for wash-up. One case showed a difference of 250-350 lost impres-

sions using the automated cleaner compared with 1,200-3,000 lost using manual washes. These systems have been shown to use approximately one-third less chemicals than manual cleaning

: (25). They can also result in two-thirds less VOC emissions and fewer waste rags. An added benefit is increased safety. Using an automatic cleaning system eliminates the risk of injury to employees holding a rag against a rotating blanket. Also, the amount of solvent used in cleaning

: is controlled, so the possibility of ignition in the dryer of paper soaked with solvent is reduced.

36

. .

VI. WASTE RUXK=TION AND RECYCLING O P P O ~ E S FOR LITHOGRAPHIC PRINlERS

r C- These systems will increase cleaning efficiency but there are some disadvantages. In general, solvents used in the automatic cleaners are more expensive than conventional blanket wash solvents. However, the decreased use of solvent will usually compensate for the difference in unit cost. Blankets and back cylinders must also be checked occasionally and may require occasional manual cleaning. Also, press cylinders washed with automatic systems usually dry slower than when washed conventionally. Finally, automatic systems do not clean as effectively and sometimes the rollers need rinsing with a vinegar and water solution to prevent glazing.

Source for more information: Refen" 3, IS, 3433

3. Improve operating practices for efficient press clean-up Press clean-up waste and cleaning chemical quantities can often be reduced with more

careful operating procedures. Management should stress to employees the importance of following established operating procedures and the importance of using chemicals and wipes efficiently. Several simple methods to reduce waste include:

Avoid drawing too much solvent from the storage container. Using a plunger-can or squeeze-bottle can reduce the risk of over-wetting rags.

Use press wipes as long as possible before discarding. Use partially-soiled wipes for the first pas, clean ones for the last wipe down.

Store press wipes wet with solvent in a closed container while not in use. This will prevent unnecessary solvent evaporation (VOC's) and reduce the amount of solvent needed for cleaning.

Recover solvent from soiled rags or paper towels with a hand operated wringer or centrifuge. Recovered solvent can be reused for press cleaning and the quantity of solvent in rags sent to the laundry will be reduced. This practice may avoid future regulatory problems.

Schedule jobs using light-colored inks before those requiring darker ones since this may reduce the number of equipment cleanings between color changes. Adopt a standard ink sequence to reduce the waste ink and cleaning solution gener ated. Dedicated presses for particular colors of ink may also be feasible in some cases, which would also result in fewer clean-ups.

Sources for more information: Refemnces 3, Id, 17,1419

4. Reduce clean up waste by cleaning ink fountains only after a color change

Keeping inks in the fountains as long as possible will reduce cleanup waste. To prevent ink drying in fountains overnight or after a run, use a commercially available spray which forms a protective film over the ink to prevent skin formation. This will reduce the need to clean fountains at the end of the day thus reducing ink and solvent waste. One printing facility

37

VI. WA!jlE REDUCIlON AND RECYCLlNG OPPORTUNITIES FOR LITHOGRAPHIC PRINlERs

. recently reported that a protective film was sprayed over each of four ink fountains on a small : offset printing press at the end of each work day. The waste ink was reduced by 5 Ibdday.

Based on a dlspasal cost of $0.70/lb and 250 operating days per year, the savings in disposal - costs were $875 per year. ALSO, the need for new ink was reduced by 5 Ibdday. At a cost of : $2.00/lb, the savings in raw material costs were $2,500/yr. The total operating cost savings : were $3,375/yr. The wst of the spray agent is relatively low. Also, less labor is needed to spray . fountains than is needed to drain and clean them out and to dispose of waste ink. This labor

saving would improve the source reduction economics. sourceS for more information: Refemnce 3

5. Increase cleaning efficiency by maintaining press clean-up equipment Maintaining the integrity of the rollers and cleaning blade, and ensuring that the blade

is placed at an optimal angle against the roller ensures good cleaning efficiency. Also, maintaining an optimal press speed during wash-up is important. The blade's angle of attack should be adjusted so that sufficient pressure is exerted on the roller, but the angle should not be so small that the blade can be "grabbed" and "pulled under" the roller. A press speed that is too slow results in long washdown times and generally increased solvent use.

Sources for more information: Refemnce 3

OPPORTUNITIES FOR RECYCLING SPENT SOLVENT Spent solvent may also be generated if it is used for the initial ink removal operation

* during press cleaning. Unless it is reused, these wastes may be a hazardous waste. Due the - quantity of solvents used by printers, recycling efforts usually have short paybacks.

1. Recover solvent from rags before laundering Cleaning rags contain a varying amount of solvent when collected for laundering. This

. solvent is beginning to cause problems for launders because the solvent enters their wastewater. : It is likely that in the future, laundries will become more heavily regulated and they will no * longer accept solvent-wet or dry ink-soiled rags.

: usable for some cleaning operations. Several options are available to printers to recOver a : portion of the solvent from the cleaning rags. The most effective removal method is centrifuga- * tion. One company reports that on the order of 2.5 to 3.5 gallons of solvent can often be . removed from a drum of waste rags. A simpler solution is to use a manual wringer. However, : this measure is most effective when implemented in conjunction with a distillation unit to purify

the recovered solvent for reuse (see measure 2 below).

Solvent in the rags also represent a loss of a raw material that if recovered may be

1- Centrifuges are currently expensive. A typical : centrifuge solvent recovery unit that could be used by a printer costs about $10,000 to $15,000.

38

e If the amount of waste rags generated is large then this measure may have an acceptable payback.

Sources for more information: References 2 + 2 Z 28

2. Use an on-site distillation unit for solvent recovery In most cases, solvent used during press cleaning must be collected and disposed of as

hazardous waste. Reducing this waste by in-house recycling can reduce raw material purchases : and disposal costs. A filtering and distillation unit can make it suitable for reuse. Reductions of

80% to 95% in virgin solvent purchases have been documented. Note that for "first pass" cleanings, contaminated solvent may be used and distilled solvent saved for the "final pass"

: :

. cleaning. C-- Distillation units cost approximately $3,OOO to :

* $5,000. However, this measure is usually economically attractive due to the significant reduction in solvent purchases.

Sources for more information: Reference 25

3. Use less toxic cleaning solvents It may be possible to substitute less toxic chemicals for the highly toxic aromatic sol-

: vents, such as toluene, benzene, carbon tetrachloride and trichloroethane. Some potential : alternatives include citrus-based products, terpenes, vegetable oils (soy-bean oil), and low- vapor

pressure mixtures of aliphatic and aromatic petroleum distillates. These specially- formulated : cleaning solvents are generally less toxic, less flammable, which will reduce VOC emissions. To : further reduce the use of solvents general clean-up detergents or soap solutions should be used

whenever possible. Solvent cleaning should be used only for cleaning ink and oils. Consult . your cleaning agent supplier for specific recommendations. k- These alternative cleaners typically cost more

than traditional cleaners, have a lower cleaning efficiency, and do not dry as fast as the more volatile agents. However, because these materials are less hazardous they are gaining popularity.

Sources for more information: References 3,s 2Q 21,2234 OPPORTUNITIES FOR VOC REDUCTIONS FROM F O U " SOLUTIONS Fountain solutions typically contain water, isopropyl alcohol (IPA), gum arabic, and

- phosphoric acid, all of which end up on the printed substrate to eventually evaporate. How- : ever, the evaporation of IPA may create a VOC emission problem. In states and regions with : stringent air quality limits on VOC's, volatile agents used in fountain solutions may require * installing air pollution control equipment.

1. Use alternative fountain solutions Alternative fountain solutions which contain little or no VOC's are currently available.

39

VI. WASTE REDUCTION AND RECYCLING OPPORTUNITIES FOR LITHOGRAPHIC PRINlZRs

* These new products are low-volatility substances that use surfactants, glycols, and glycol ethers *

in lieu of IPA. Printers that have switched to alternative solutions generally have found that they : : perform satisfactorily, but an adjustment period for press operators to learn how to "fine-tune" :

the equipment to accommodate the new solution should be expected. Roller setting may require *

: adjustment to accommodate the change in wetting characteristics. Instrumentation which : measures inWwater balance will aid in the initial adjustments.

: reports that even though the new solution requires tighter tolerances and greater operator A printing company that has made the conversion to an alternative fountain solution

attention, several distinct benefits had been attained including: Printing quality has improved because presses must run on tighter inWwater

Pres rollers do not shrink as they do with alcohol, and require less frequent tolerances and negative effects of alcohol on ink are eliminated.

replacement.

reducing the need for replenishment. The substitute solutions are less expensive because they evaporate slowly, thus

Sources for more information: References 3,5, 7, 2Q 23,24

40

E-

: VII. The Screen -- Printing Process -

And Associated Waste Generation __

41

VII. The Screen Printing Process and Associated Waste Generation

A. Background Screen printing accounts for approximately 3% of the printing market. It is commonly

used for printing signs, wallpaper, textiles, greeting cards, ceramics, decals, and banners. Print- ing facilities involved with screen printing generally use the following operations:

Image processing Screen making Printing Screen reclamation Finishing

Other sub-operations include proofing, ink dlying, and press cleaning. Smaller facilities may contract with outside vendors to perform the image processing and finishing operations.

porous mesh carrying an outline of the image. The printing area is porous and is delineated from the non-image areas by a chemical or mechanical stencil. During the printing process, screens are attached to the press in a frame-work. Ink is then applied and brushed through the screen with a squeegee. After a printing run, screens are cleaned for reuse. A flowsheet of the typical operations performed in a Screen printing facility is presented in Figure 2 (page 44). A more detailed screen printing process description, useful in training inexperienced employees, is presented in Appendix VI1 (page 67).

In screen printing, an image is transferred to a substrate by forcing ink through a

43

VII. THE SCREEN PRINTING PROCESS AND AssocIATED WASTE GENERATION

Figure 2. Screen Printing Process Flow Diagram

Art Work, Computer Image, or Copy

1 Exposed and Waste Film

Empty Chemical Containers

Spent Processing Chemicals and Wastewater

Waste Proofs

Screen Material

Wire Mesh, or Stainless Steel)

Stencil Material (Light Sensitive Emulsion,

(Silk, Nylon, Polyester, - Empty Chemical Containers

Damaged or Unusable Screens Scrap Stencil Material Wastewater From Unexposed Emulsion Removal

Unacceptable Prints VOC Air Emissions Waste I Ink Solvent Soiled Rags and Paper Wipes Damaged or Unusable Screens

Ink - Substrate Material - (Paper, Plastic. Fabric)

Cleaning Solvents ___+

Rags or Paper Wipes -

1 Paper - Paper Scrap

Plastic Scrap Lacquer Waste

Glue / Adhesives - Plastic or Lacquer -

+ Finished Product

44

VII. THE SCREEN P F U " G PROCESS AND AssocIATED WASTE GEmRATlON

B. Common Waste Disposal Practices for Screen Printers Each operation in the printing process is characterized by a number of recurring waste :

* * streams which the printer must deal with. Table 2 l i waste streams that are commonly encoun-

tered and the typical methods that are used for disposal.

. .

Table 2. Waste Streams and Disposal Practices for Screen Printing

TYPICAL DISPOSAL PRACTICES* I : WASTESTREAM UNIT OPERATION

IMAGE PROCESSING Discarded with municipal waste I : Exposed unusable film May be recycled for its silver


Discharged to the Publicly

content

or recyded

Owned Treatment Works (")

(May require Pretreatment prior to discharge)

Fwing solutions may be recycled for their silver content

Discarded with municipal waste Film may be recycled for its


Discarded with municipal waste Discharged to the POW

silver content

or recycled

Empty photoprocessing chemical containers Wastewater [(containing developers, fwers (with silver), rinse waters, reducers and intensifiers)]

PROOFING Waste film and paper

SCREEN MAKING Empty chemical containers

Damaged screens Wastewater from unexposed emulsion removal (May require pretreatment prior

to discharge)

Scrap stencil material Discarded with municipal waste

PRINTING Off-specification prints Discarded with municipal waste or recvcled

VOC air emissions Vented to atmosphere May require control (destruction or capture) before release

Damaged screens Discarded with municipal waste

Soiled paper wipes May require disposal as hazardous waste otherwise discarded with municipal waste

45

WI. W E SCREEN P R " G PROCESS AND AssoclAlZD WASTE GENERATION

Spent solvent (removed from wipes before disposal)

Wastewater (from ink, emulsions, and haze

Spent solvent (ink removal)

Table 2. Waste Streams and Disposal Practices for Screen Printing continued

(May require disposal as hazardous waste)

Shipped off-site for use in a fuels program

May be recycled on- or off-site

Discharged to POW (May require pretreatment prior

to discharge

Shipped off-site for use in a fuels program or recycled on- of off-site

UNIT OPERATION

PRINTING (continued)

Damaged screens

Scrap paper, plastic, or other printing medium

SCREEN RECLAMATION



TW3HING ~~~

Waste glue, adhesives, and lacquer

WASTESTREAM

Shipped off-site for use in a fuels program or recycled on- of off-site

~ ___

Soiled cloth cleaning rags

Empty ink containers

May be laundered on- or off-site May require disposal as hazard-

ous waste otherwise discarded with municipal waste


Bulk containers are refilled by the supplier

Waste ink and solvent mixture from equipment cleaning

Commonly d i e d with municipal waste by small companies after drying

~~~~

VOC emissions I Vented to atmosphere May require control (destruction or capture) before release

. * These methods may or may not be in compliance with regulations applicable to your facility. You are responsible for evaluating . your waste streams to determine their regulatory status,

46

VIII. Waste Reduction Opportunities For Screen Printers

47

: VIII. Waste Reduction Opportunities for Screen Printers

A. Introduction Pollution prevention measures SUG I as improving ,,ousekeeping, recycling waste

* streams, and optimizing operating procedures covered for lithographic printing also apply to screen printing. These ideas are easily implementable and can produce significant waste

: reductions. For a detailed discussion of these actions, refer to Section VI (page 23).

B. Waste Reduction Through Inventory Control Inventory control techniques can minimize the waste created from raw materials, such

* as inks, expiring before being used. The techniques applicable to lithographic printing are also - applicable to screen printing. As a result, refer to Section VI, B (page 26) for information.

C. Waste Reduction Measures for Image Processing A common thread between lithographic and screen printing is image production. The

: process is identical for each type of printing. For detailed information on reducing waste film, mylar, developers, and other wastes from image production, please refer to Section VI, C (page 27).

D. Waste Reduction Measures for the Screen Printing Process

OPPORTUNITIES FOR REDUCING SCREEN RECLAMATION WASTE Screen reclamation activities typically generate a solvent waste and wastewater. VOC

emissions may also be associated with the solvent used to remove ink and emulsion.

1. Dispose of screens that will not be reused If screen reclamation activities create regulatory and disposal problems, a viable option

- may be to discontinue reclamation activities altogether. This would eliminate the cost of replen- . ishing and disposing of hazardous chemicals used for ink, emulsion, and haze removal. How- : ever, the cost of purchasing new screen material would result.

r Ca-- This measure could potentially result in a new . (non-hazardous ) waste disposal concern, especially for large printers.

49

VIII. WASTE REDUCllON 0PPORlU"ES FOR SCREEN PRINERS

2. Use automatic screen washers for screen reclamation Totally enclosed systems are commercially available for ink, emulsion, and haze

* removal or ink only removal. These systems can reduce the quantity of chemicais necessary for

: reduced.

- be prohibitive for small printers at this time.

Screen cleaning and reduce air emissions. Labor involved with screen cleaning will also be

2 These systems are currently expensive and may

3. Increase ink removal efficiency In most ink removal operations, an equivalent degree of cleaning could be achieved

. while reducing the quantity of solvent used. Using low-flow spray nozzles to apply solvent : directly and evenly will minimize the solvent "blowing through" the screens. Once applied, * solvent can be brushed thoroughly into the Screen. Reducing solvent use will lower annual costs - of raw material as well as both liquid waste and air emissions.

Sources for more information: References 24 26

4. Increase emulsion removal efficiency An alternative technique for emulsion removal is to use a high-pressure water blast

: which has been demonstrated to be effective. The high velocity fluid impacting the Screen : loosens the emulsion and increases the removal efficiency. Pressures of 4,000 psi have been

used without damaging screens. The combination of this and previous measures could poten- : tially reduce emulsion remover by as much as 75%.

Sources for more information: References 24 26

5 . Reduce the use of haze remover Using haze remover can cause screens to become brittle and tear more easily as well as

contributing chemicals to the wastewater stream. Therefore, it is beneficial to minimize its use. * Several simple techniques can be used to accomplish this reduction:

Apply haze remover only to the affected area instead of over the entire screen. Avoid allowing used screens to sit for a long period of time before reclamation as the

longer ink and emulsion remain on the screen the more likely "ghost" images will form.

formation. Apply an ink degradent to the screen before reclamation to prevent "ghost" image

Sources for more information: References 2426

50

VIII. WASTE RuxKJnON OPPORTUNITIES FOR SCREEN PFUNTERS

OPPORTUNITIES FOR PRESS AND SCREEN CLEANING WASTE REDUCTION Press-side screen cleaning and press cleaning are done in part by using solvent-wetted

rags or paper wipes. Contaminated rags and wipes may be regulated as hazardous waste and . can be the source of regulatory problems. Also, significant VOC emissions are associated with : press cleaning operations.

1. Reduce solvent used for press and press-side screen cleaning Screen printing requires solvents to clean the press and screens after a printing run.

: Several simple procedures can reduce the quantity of solvent used for press-side screen cleaning - and the associated VOC emissions: Minimize the solvent applied to a rag by using plunger cans or squeeze bottles. Use press wipes as long as possible before discarding. Use soiled wipes for the initial

Store rags between use in closed containers to avoid solvent evaporation. Store used solvent-wetted rags in a closed container to avoid solvent evaporation.

pass and clean ones for the last.

This practice will reduce VOC emissions and later increase solvent recovery if a wringer or centrifuge is used.

OPPORTUNITIES FOR VOC REDUCTION The most common screen printing inks are oil-based which dry through solvent wapo-

ration. This drying process is associated with high VOC emissions. VOC emissions can create * regulatory problems for printers, especially those located in nonattainment areas as designated

under the Clean Air Act Amendments of 1990.

1. Use UV inks for printing W-curable inks are widely used in the printing industry for printing primarily on

- plastic, vinyl, metal, and paper substrate. These inks contain no VOC's. Instead, curing is by . ultraviolet light-induced polymerization. These inks will not dry on a press so cleaning require- : ments may also be reduced. Some reported advantages of W curables include:

Decreased or eliminated VOC emissions Less frequent press cleaning and associated solvent use Reduction in required floor space (eliminates need for drying ovens or racks) Increased throughput Reduced health and safety hazards associated with solvents b- On the negative side, the following barriers have

In many cases performance is not as good (insufficient opacity and color matching) Substrates with deeply textured surfaces are not currently suitable for W-curables Outdoor durability may be a problem

been reported by screen printers using W curables:

51

U11. WASTE FEDUCTION OPPORTUNmEs FOR SCREEN PFWTER!j

UV curables are brittle and finishing operations like die cutting and molding present

Worker safety issues (exposure to ultraviolet light and certain chemicals in the inks) The capital investment is very high for conversion to UV systems Small printers may not experience the increased production speed and ink cost/

Sources for more informa~on: Refenmce 29

problems

coverage benefits due to shorter average runs

52

Appendix I. Bibliography

* 1.

: 2.

3.

- 4.

: 5.

* 6.

. 7.

8.

: 9.

: 10.

: 11. 12.

13. : 14.

15. - 16.

Of The Economic and Technology Transfer Division, . . . Office of Pollution Prevention and Toxics, U.S. Environmental Protection Agency Washing ton, D.C., May 26,1992.

&QQ& Regulatory Impacts Branch, Economic and Technology Division, office of Pollution *

Prevention and Toxics US F A , July 14,1992. US F A . Guide to 2

P o b . .

. . EPA/625/7-90/008, August 1990.

1- The . . University of Tennessee Center For Industrial Services Waste Reduction A s s i i c e Program Nashville, Tennessee, 1989. A G u i c k W U b Prevention For: 1 Prepared for Printing Industries of New England by Tufts University, Department of Civil Engineering, Medford, Massachusetts, August 1991.

"NAPL Special Report Water Quality Regulation And Their Affect on Printers", National Association of Printers and Lithographers Research & Educational Foundation, August 1991. Pferdehirt, Wayne, I? "Roll the Presses but Hold the Waste: P2 and the Printing Industry", P o l l u t i o n v i e w Vol3, No. 4, 1993, pp 437-464. Bruno, Michael H. Michael H. -89 90. A Rep~~t.: GAMA Communications, Salem, New Hampshire, 1990.

Task Force, Printing Industries of America Alexandria, Virginia. SRI Project 7656, August 1990.

McMichael, Stu. Advis-: An Environmental Casdhdy, Printing Industries of America Alexandria, Virginia, April 1992. Scarlett, Terry. "Inks Getting Bad Environmental Rap", ' June 1992,p81. : Campbell, Monica E. and William M. Glenn.

Toronto, Ontario, Canada, pp 201-215. "Soy Ink Just Full of Beans?", Scarlett, Terry. "Soy Sense", "Soybean Oil Inks Gaining Market Acceptance", Pollution P r e v m July 1991. "NAPL Special Report: How Printers Dispose of Their Shop Towels", National Association of Printers and Lithographers Research & Educational Foundation, April 1992.

:

.

- ' . .

Prepared by SRI Intemational, Menlo Park, California for the Printing 2000 : :

. .

. u

Prevention. A G W Waste Published by Pollution Probe Foundation

July/August 1991, p 45. , May 1991, pp 38-40.

53

APPENDIX 1. BIBLIOGRAPHY

17. "Case Study: Managing Solvents and Wipers", iew, Autumn 1991, pp 419-424.

e 19. Case Study: M V Wines, EPA Design for the Environment Printing Project. EPA 744-F-93-015, 1993.

California Environmental 20. Pollution Prev) Protection Agency, Department of Toxic Substances Control and County of Sacramento Hazardous Materials Division, Doc. No. 519, April 1991.

: 21. Hendriksen, IC, J. Parking, and S. Haagensen. "Soya-Bean Oil as a Cleaning Agent for Offset Printing Presses", Advances in Printing Sciences and Technology, Proceedings 20th International Conferences of Printing Research Institutes, Pentech Press, London, 1990.

EPA Design for the Environment

. .

I Jse : 22. ~ O u t l ~ f o r ~

Printing Project, March 10, 1993.

Office of Technical Assistance Executive, office of Environmental Affairs, C101-3, Boston, Massachusetts, September 1993.

- 24. "NAPL Special Report: Alcohol Substitutes Find Increased Acceptance: If at Erst You Don't Succeed, Try Again", National Association of Printers and Lithographers Research & Educational Foundation, September 1990.

23. 3hxic Use Redudion Caw S- FQ- at

. . . . 25. 1 EPA 744-F-93-015, 1993

26. Intduby Outline for k e r T e h : en EPA Design for the . .

Environment Printing Project, March 10, 1993.

WiDes. Minnesota Technical Assistance Program, University of Minnesota, Minneapolis, Minnesota, (612) 625-4949.

Program, University of Minnesota, Minneapolis, Minnesota (612) 625-4949.

Prepared for U.S. Environmental Protection Agency Ofice of Research and Development, Washington D.C., Prepared by TRC Environmental Corporation Chapel Hili, North Carolina. EPA Contract No. 68-D2-0181.

: 27. :Towels-

: 28. MnTAP F- For .- Minnesota Technical Assistance

: 29. to-in

: . . . .

-

* 30. "Disposal and Treatment of Photographic Wastes, In Support of Clean Water", Kodak Publication No. 5-55, 1988.

APPENDIX 1. BIBUOGRAPHY

* 31.

: 32.

: 33.

: 34.

* 35. * 36.

37.

* 38.

* 39.

"CHOICES-Choosing the Right Silver-Recovery Method for Your Needs", Kodak Publica tion No. 5-21, Eastman Kodak Company, Rochester, New York. "Cleaning Up the Cleanup: Shepards Poorman's Switch to Automatic Washup for Sheet- fed Presses" QXTFWOFLR, Vol. 4, lssue 4,1992, pp 33-35. Hicks, Jennifer. "A Clean Sweep: Reduced Makeready, Print Quality Guide Move to Automatic Blanket Washers", ' August 1991, pp 34-36. Peterson, Debbie. "A Delicate Balance: Weighing the Merits of Replacing High-VOC Chemicals With "Friendly" Substitutes to Slash Air Emissions", ' August

Cross, Lisa. "Answers About UV.", . Vol. 1 of a ANCHOR Technical Staff. The Fundian of Fo]

series of technical publications. Orange Park, Florida. ANCHOR Technical Staff. technical publications: Orange Park, Florida.

, John Wdey Kirk-Othmer. 1 & Sons, New York, New York 1982, pp 110-163. Theodore, Louis and Young C. McGuin. New York 1992, pp 229-239.

1991, pp 26-29. September 1990, pp 92-94. . . .

' . Vol. 1 of a series of . .

..

* , Van Nostrand Reinhold,

55

Appendix 11. Overview of Hazardous Waste Generator Status

In a climate of constantly changing regulations and emerging new waste management philosophies, it is often difficult for the small printer to keep track of accepted waste disposal and management practices. Depending on the amount of waste produced, printers may be subject to different solid and hazardous waste regulations under the Resource Conservation and Recov- ery Act (RCRA). To assist your company find how it fits into the regulatory picture, the following brief discussion of the different generator statuses is provided.

Conditionally Exempt Small Quantity Generator Many printers fall into this category since the industry is characterized by a large

number of small shops employing 20 people or less. To be classified as a Conditionally Exempt Small Quantity Generator (CESQG) a facility must:

Identify all hazardous wastes and keep documentation of the identification process. Generate no more than 220 pounds of hazardous waste in a month. Accumulate no more than 2,200 pounds of hazardous waste on-site at any time. Either treat or dispose of hazardous waste in an on-site facility or ensure delivery to

an off-site treatment, storage, or disposal facility approved by the regulating agency (either the state or the US EPA).

Small Quantity Generator Generators that produce between 220 pounds and 2,200 pounds of hazardous waste

in a month are classified as Small Quantity Generators (SQGs). SQGs are subject the requirements of CESQGs as well as the following additional requirements:

Waste must be disposed of within 180 days of when the waste begins to accumulate

Accumulate no more than 13,200 pounds of hazardous waste may be stored at any

An EPA identification number must be obtained for the plant. SQGs must comply with all marking, labeling, placarding, and manifesting require-

SQGs must file an annual report to the state EPA office on March 1 of each year. SQGs must be prepared for a hazardous waste emergency by complying with all

emergency coordination and preparedness and prevention requirements. SQGs must inspect hazardous waste storage areas weekly for leaks and container

deterioration. SQGs must have prepared and submitted a hazardous waste reduction plan to the

Tennessee EPA office by January 1,1994.

(270 days if the waste is shipped over 200 miles).

one time.

ments prior to and during shipment of hazardous waste.

57

APPENDIX 11. OVERVIEW OF HAZARDOUS WASTE GENERATOR STATUS

Large Quantity Generator Most printers are classified as either CESQGs or SQGs. However, some of the largest

: companies may find that they fall into the categoy of Large Quantity Generator (LQG). LQGs * are facilities that generate more than 2,200 pounds of hazardous waste in a month. In addition . to those requirements stated above, LQGs musk

Dispose of hazardous waste within 90 days frbm when its accumulation begins. Have a written hazardous waste emergency contingency plan. Provide hazardous waste management training to employees, including contingency

For more detailed information regarding LQG requirements, contact The University of plan implementation.

* Tennessee's Center for Industrial Services at (615)532-8657.

58

Appendix 111. Code of Federal Regulations Titles Applying to Printers

:

Copies of the Code of Federal Regulations (CFR), Title 40, ,may . be purchased from the US. Government Printing Ofice, Superintendent of Documents, Washington, D.C. 20402-9328.

A. RCRA Titles that Apply to hinters Part 260- Part 261- Part 262- Part 264-

Part 265 -

Part 266 -

Part 270 -

Hazardous Waste Management System: General Identification and Listing of Hazardous Waste Standards Applicable to Generators of Hazardous Waste Standards for Owners and Operators of Hazardous Waste Treatment,

Interim Status Standards for Owners and Operators of Hazardous

Standards for the Management of Specific Tvpes of Hazardous Wastes

EPA Administered Permit Programs: The Hazardous Waste Permit Program -

Storage, and Disposal Facilities

Waste Treatment, Storage, and Disposal Facilities

and Specific Tvpes of Hazardous Waste Management Facilities

B. Clean Water Act Titles that Apply to Printers 40 CFR, Subchapter D

Part 110- Part 112 - Part 114 - Part 116 - Part 117 - Part 122 - Part 125 -

Part 129 - Part 136 -

Part 403 -

Part 459 -

Discharge of Oil Oil Pollution Prevention Civil Penalties for Violations of Oil Pollution Prevention Regulations Designation of Hazardous Substances Determination of Reportable Quantities for Hazardous Substances WA Administered Permit Programs: The National Pollutant Discharge

Criteria and Standards for the National Pollutant Discharge Elimination

Toxic Pollutant Effluent Standards Analytical Methods Required when NPDES Permit Establishes a

General Pretreatment Regulations for Existing and New Sources of

Photographic Point Source Category

Elimination System

System (NPDES)

Limitation 40 CFR, Subchapter N

Pollution

59

APPENDIX 111. CODE OF FEDERAL REGULATIONS TITLES A P P L . G TO PRNER!j

C. Clean Air Act Titles That Apply To Printers Title I, Part A, Section 112, National Standards for Hazardous Air Pollutants Title V, Permits Title VI, Stratosphetz Ozone Protection

60

: Appendix IV. Sources for Information on Tennessee State Hazardous Waste Regulations

Tennessee Department of Solid Waste Management Offices telephone numbers:

Memphis ........... (901) 529-6695 Jackson ............. (901) 424-9200 Nashville ........... (615) 741-0654 Cookeville ......... (615) 432-4015 Chattanooga ..... (615) 624-9921 Knoxville ........... (615) 594-6466 Johnson Ci ty..... (615) 928-6487

61

Appendix V. RCRA Solvents

A. Currently Listed Solvents F00l

F002

FOO3

FOo4 F005

Halogenated solvents used in degreasing: Tetrachloroethylene, trichloroethyl ene, methylene chloride, l,l,l-trichloroethane, carbon tetrachloride, and chloronated fluorocarbons. Halogenated solvents: Tetrachloroethylene, trichloroethylene, methylene chloride, 1,1, I-trichloroethane, chlorobenzene, 1,1,2-trichloro-l, 1,2- trifluoroethane, orthodichlorobenzene, trichlorofluoromethane, and 1,1,2- trichloroethane. Ignitable non-toxic solvents: Xylene, acetone, ethyl acetate, ethyl benzene, ethyl ether, methyl isobutyl ketone (MEK), n-butyl alcohol, cyclohexanone, and methanol. Toxic non-halogenated solvents: Cresols, cresylic acid, and nitrobenzene. Ignitable toxic solvents: Toluene, MEK, carbon disulfide, isobutanol, pyridine, benzene, 2-ethoxyrthanol, and 2-nitropropane.

B. Solvents for Possible Future Listing Solvents 111 (Proposal by April 1994, Final by June 1995): Cumene, phenol,

isophorone, acetonitrile, furfural, epichlorohydrin, methyl chloride, ethylene dibromide, benzyl chloride, and p-dichlorobenzene.

methoxyethanol, 2-methoxyethanol acetate, 2-ethoxyethanol acetate, and cyclohexanol.

Solvent Study (Due September. 1996): Diethylamine, aniline, ethylene oxide, allyl chloride, 1,4-dioxane, 1,l -dichloroethylene, and bromoform.

Solvents I1 (Proposal by September. 1997, Final by September. 1998): 2-

63

Appendix VI. Sources of VOCs in the Printing Industry

Many different chemicals are used in the printing industry because there is such a wide : variety of substrates and intended uses of final products. Many of these chemicals are classified * as "volatile organic compounds" (VOCs) which may cause emission-related regulatory prob- . lems. The following l i includes the most common VOC's that are used in the printing industry : and regulated by the CAA.

Acetone Butanol (Butyl Alcohol) Carbon Tetrachloride Ethanol (Ethyl Alcohol) Ethyl acetate Ethylene glycol Glycol ethers Glycol esters Glycol ether esters Heptane Hexane

Isopropanol (isopropyl alcohol) Isopropyl acetate Methanol (methyl alcohol) Methyl chloroform (trichloroethane) Methyl Ethyl Keytone Methyl isobutyl keytone Mineral spirits Napthas Normal propyl acetate Propanol (propyl alcohol) Stoddard solvent

lsooctanol (isooctyl alcohol) Toluene Xylene

65

: Appendix VII. Detailed Printing Processes Descriptions

A. Lithographic Printing

1. Image Processing Most printing jobs begin with either a hard copy or computer file of art work, text, or

some other kind of image. The images are transferred to film using graphic arts photography. The film is then developed and a proof is made for customer review. Developed film is used to "bum" an image onto a lithographic plate.

Film developing is typically a manual "tray" operation for very small companies or it is

immersed in a developer where the silver halide emulsion coating is converted to metallic silver. : automatic in a continuous photoprocessor for medium and large printers. Exposed film is '

. The most common developing agents are metol and hydroquinone, but some developers may : contain other benzene derivatives including pyrogallol, catechol, p-phenylene diamine, p- a aminophenol, amidol and pyramidol. The developing bath also contains an alkaline accelerator - compound (sodium hydroxide, sodium bicarbonate, or sodium tetraborate), a preservative

(sodium sulfite), and a restrainer (potassium bromide). The accelerator compound increases the : activity of the developer by neutralizing acid formed during developing. The preservative

reduces oxidation damage to the film and the restrainer minimizes the formation of "fog". The developing process is stopped by immersing the film in a fucing solution, which

: converts the silver halides to soluble complexes, thus preventing them from converting to metal- * lic silver. Fucing compounds typically contain sodium thiosulfate ("hypo"), ammonium sulfate, or . sodium hyposulfite. Other components of this bath include acetic acid, sodium sulfite, potas- : sium alum, and boric acid. Potassium alum prevents excess swelling of the photo-emulsion * gelatin. In a basic or neutral environment the potassium alum is not stable and a precipitate of

aluminum hydroxide will form. To prevent this from occurring, acetic acid is added to maintain : a low pH. "Hypo" decomposes in an acidic solution resulting in the formation of a precipitate of * elementary sulfur. Thus, sodium sulfite is added to the bath to react with the sulfur precipitate

and form more sodium thiosulfate. Boric acid buffers the solution to limit pH changes. As the photographic emulsions are futed, a small amount of silver is released into

: solution. When the silver concentration reaches a threshold level, insoluble compounds, which cannot be removed, are formed in the emulsion. Therefore, the bath must be replaced before this critical concentration (2 gramdl) is reached.

Residual chemicals including "hypo" remain in the gelatin emulsion layers after nega- tives or positives have been fixed. If "hypo" is not removed from the emulsion, it will react with

. the silver and complex silver salts to form a yellowish brown silver sulfide that impairs image : quality. To prevent sulfide formation, the "hypo" and other fwing chemicals are rinsed from the - emulsion in a still water bath or in a running water rinse.

In manual developing operations, developers, fwers, and rinse waters are poured into : open trays. Film is then sequentially placed by hand in each tray for a predetermined time. * Photoprocessing chemicals are added manually to the bath as needed. The frequency and - amounts of additions are typically left to the operator judgment.

67

Automatic developers usually contain three internal tanks in which the processing : solutions are held. Undeveloped film is fed into the machine on a conveyor which travels

. tanks from outside storage containers at rates specified by the equipment manufacturer. sequentially through each bath. Chemical additions are injected automatically into the internal

2. Plate-Making Lithographic printing uses a flat metal or paper plate as an intermediate image carrier

: which transfers an inked image to a rubber blanket. The blanket then transfers the image to the * substrate. Plates used in lithographic printing are generally photomechanically- or electrostati-

cally-made surface plates. Surface plates have a light-sensitive coating which becomes ink- : receptive when exposed to light. Other types of plates include deep-etch plates and bimetal

plates, but these are quickly becoming obsolete due to water pollution problems associated with . their production.

Photomechanical surface plates are the most common image carrier. These are made from thin anodized or grained aluminum plates which have been coated (usually by the manu-

* facturer) with a light-sensitive material. An image is transferred to a plate in a vacuum frame or . "step-and-repeat" equipment. An image transparency is placed over a lithographic plate. Next, : a framed glass sheet is placed over the transparency and a vacuum is applied to pull it tightly * against the glass. The plate is then exposed to ultraviolet light which is passed through the . transparency. The coating on the exposed areas of the plate undergoes a change in its physical

properties making the image insoluble to water or other solvents. If the transparency is a photographic negative, light passes through the non-silvered image areas and is blocked by the

. silver in the non-image areas. The most common plate coatings are diazo compounds and : photopolymer resins. Other coatings which are used include asphalt, shellac, gum arabic, and : polyvinyl alcohol.

: tive. With additive plates, a one step emulsion developer containing an oleophilic resin is used to make the hardened image areas ink receptive. Subtractive plates usually have an oleophilic - resin incorporated into the coating or applied as a lacquer over the coating. When a plate is

: placed in the developer solution, the non-image coated area dissolves. Electrostatic plates are non-metallic paper plates. The same process that is used to

* make office copies is used to make electrostatic plates. They are coated with a photoconductor . which is ionized by an electrophotographic camera. The charged paper is exposed to the : reflection of light from the image or copy to be reproduced. The white areas of the image reflect

light to the plate and cause a dissipation of the charge on the image areas while the dark areas . of the image absorb light and the electrostatic charge remains on these plate areas. Liquid toner, : which is attracted to the charged areas, is applied to the plates to form a visible image. The * toner attracts ink and the rest of the paper is water receptive during press operation. To enhance - the plates acceptance of water, they are dampened with an etch solution typically containing

hydrogen and sodium cyanides.

After plates have been exposed they are developed. Plates can be additive or subtrac-

68

APPENDIX VII. DETAILED PRINTING PROCE!SES DESCRIPTIONS

3. Printing Most lithographic printing is performed with mechanical presses. Three major areas

: are common to each printing unit on all lithographic presses: Dampening system Inking system Image transfer

A single color is printed with each print unit. Multi-color printing is done by overlaying the four basic colors (black, magenta, cyan, and yellow) sequentially. On a multi-color press,

: each color is applied to the substrate in each (usually four) print unit. Single color, or single unit, * presses apply one color per press run. As a result, multi-color print jobs on single unit presses - require multiple press runs.

: a press. As the cylinder rotates during a printing run it contacts several small rotating rubber . rollers which transfer ink and a dampening (fountain) solution to the plate. The inked image is : then transferred to a soft rubber "blanket" which in turn transfers the image to the printing : substrate.

The dampening system meters and distributes the fountain solution to the image- . carrying plate. A rubber roller picks up solution from a fountain and transfers it to a second : roller or several rollers from which the solution is applied to a plate. The speed of the rollers

controls the amount of dampening solution transferred to the printing cylinder. Speed is ad- . justed until an optimal ink-to-water ratio is reached. The primary functions of the dampening : solution are to:

After plates are prepared they are wrapped around and fastened to a metal cylinder on

Prevent ink flow into non-image areas. Provide a uniform flow and ink film thickness across the plate. Produce a sharp boundary between the image and non image areas. Clean ink from non-image areas between runs. Minimize frictional wear and to prevent overheating of the ink train and plate

surface. Fountain solution performs optimally at approximately 68°F therefore, it is typically

circulated through a chiller. Also, it may be filtered to remove solublized ink residuals and paper : lint. The solution is circulated through the system and into the fountain reservoir to be picked up * by the water roller. Tvpical fountain solution chemicals include isopropanol, 2-butoxyl ethanol,

gum arabic, ethylene glycol, dipropylene glycol, and synthetic cellulose. The inking system consists of a series of distributor, dudor, vibrating and form rollers.

Ink is metered from a fountain onto a roller. The amount of ink released at sites across the roller is controlled by fountain keys which are manually or automatically adjusted. A ratchet handle

*

: controls the sweep or arc of rotation of the fountain roller. A roller train mills the ink prior to * delivery to the form rollers to produce a uniform film applied to the plate.

As ink and fountain solution are transferred to a plate they behave like oil and water, separating as the water-based solution is attracted to the non-image areas and the ink is drawn

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APPENDIX VII. DETAILED P R " G PROCESSES DESCRIPTIONS

: toward the image areas. As an optimum ratio of the two liquids is achieved, a sharp boundary : will formed a distinct image.

Adjustment (makeready) of press parameters is generally required before beginning an : actual printing run. Adjustments include sheet position, registration accuracy, inWwater balance, ' and color density. During this process, sample sheets of paper are printed to determine the need . for further adjustment. Makeready prints become a waste that is often recycled.

: chemistry involved with the image transfer system. These i n k may contain solvents including * xylenes, ketones, alcohols, or aliphatics. These compounds are emitted as VOCs to the atmo- - sphere as inks dry.

Following a printing job or a color change, press components must be cleaned. The * frequency of press washes depends on factors such as dust and dried ink accumulation and

paper quality used (lint contamination may occur when low quality paper is used). Ink rollers and plates are typically cleaned in-place. An operator rotates the rollers while pouring solvent

: over it with a squirt bottle or other applicator. Residual ink is dissolved in the solvent and cut * (scraped) from a roller with a blade. The resulting waste solvent/ink mixture is collected in a tray. - The tray and blade are a single unit that is temporally attached to the press during cleaning. : Blankets are cleaned during and following a run or after a color change. Most blanket cleaning : is done with rags wetted with solvent. Solvent is applied to rags with plunger cans, squirt bottles, * recycled gallon jugs, or open pails into which rags are dipped. An operator then wipes clean the . inked blanket. Solvents used for cleaning include methanol, toluene, naphtha, trichloroethane,

methylene chloride, and a variety of specially-formulated solvent blends. Generally the same - solvent is used for blanket and roller cleaning. However, a more aggressive solvent ("glaze

remover") is occasionally required to clean deep-seated ink which accumulates in the ink roller

Inks for lithographic printing are generally oil-based. This is essential due to the

. pores.

4. Finishing The finishing process includes the following operations: trimming, folding, collating,

. binding, laminating, and embossing. Scrap paper is the most prevalent waste generated during * these operations. Several binding methods used include stitching, gluing, and mechanical - binding. During stitching, a metal staple binds the product and no adhesives are necessary. : Gluing can be a hot-melt process where solid chips of glue are melted onto the bind of the

product or a paste and press process which typically uses a water polyvinyl acetate resin.

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APPWIX VI1. DETAlLED P F U " G PROCmES DESCRIPTIONS

B. Screen Printing

1. Image Processing Image processing operations for screen printing are generally the Same as those used in

. lithographic printing. Therefore, a separate discussion will not be provided here and readers : should refer to the image processing description in Appendix VI1 (page 67).

2. Screen Making In Screen printing, a porous mesh screen with an ink-resistant image on its surface is

used as a template to transfer ink to the substrate. Screen material depends on the type of substrate used as well as the desired appearance of the product. Screens can be made of silk

: bolting cloth with a taffeta weave and typically have mesh counts of 40 - 80 openings per linear : centimeter. Nylon screens are generally used for textile printing and metal screens made of - phosphor bronze and stainless steel in meshes as fine as 120 openingdan are used for fine detail - printing.

: frame so that it is level and smooth. Non-image areas of the screen must be blocked and image * areas remain open to allow passage of ink. The image can be transferred to a Screen in a . number of ways.

* film. The image to be printed is cut through one layer of the material and removed. The remain- - ing stencil material is placed in contact with the underside of the screen. A solvent is then : applied that "welds" the stencil to the screen and then the back-layer of the stencil is peeled off : leaving only the image area of the screen.

More commonly used in screen making is a direct coating photomechanical stencil in . which an emulsion of bichromated gelatin or bichromated polyvinyl alcohol (WA) is applied to

the screen's surface. The emulsion is smoothed and leveled either manually with a squeegee or * automatically. When the coating has hardened, the screen is exposed to UV light though a - positive. The emulsion, through a photochemical reaction, becomes insoluble when exposed to : UV light. Next, the unreacted emulsion, which is still water soluble, is washed off with water.

Screen preparation begins by tightly stretching and securing the material in a rigid

A stencil made of two plastic layers can be made manually by knife-cutting a special

3. Printing Screen presses can be quite simple. Usually they consist of a table, screen frame, and

: a squeegee. Many small printers use this type system. More complex mechanical presses with * automatic substrate feeds are commonly used by the larger printers. Some of these systems can - produce 450 to 3500 prints per hour. Rotary screen presses are also seeing increased use. : Improvements on speed, print quality, and the range of products produced can be realized with

thesepresses.

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APPENDIX VII. DETAILED PRINTING PROCESSES DESCRlPllONS

During printing, ink is applied to the screen and brushed across it with a squeegee to force the ink through the porous image areas onto the substrate. This process may be either manual or automatic. Automatic systems provide better control of factors such as squeegee angle, pressure, and blade speed, all of which affect print quality. The most common inks used for screen printing are solvent-based inks. Other screen printing inks include W, plastisols, and water-based formulations.

Rotary presses, often used in textile and wallpaper printing, use thin seamless metal cylinders onto which an image has been etched. The cylinders are porous in the image areas and solid metal in the non-image areas. Cylinders are capped at both ends and ink is pumped into one end to maintain a fresh supply during printing. The squeegee is a floating metal bar inside the cylinder, the tension of which is adjusted by magnets mounted under the p r e s bed.

use. Before removing the screen from a press, a blade is used to manually scrape residual ink from the screen. Solvent-soaked rags or paper wipes are used to remove the remaining ink. h g s and paper wipes are also used for press wipe-down. Ink removed from screens may be saved for future use or discarded if contaminated or overly dry.

After a printing job, screens are removed from a press and may be reclaimed for future

4. Screen Reclamation After completing a printing job, screens are often cleaned and reused in future printing

runs. Screen reclamation is generally a three-step operation. Initially, any residual ink on a screen is removed with a solvent. Typically, the solvent is sprayed directly onto the screen. Common ink removal solvents used include dhmonene-based products, glycol ether and dibasic ester blends, mineral spirits, methyl ethyl ketone, acetone, butyl solusol, cyclohexanone, toluene, and methyl isobutyl ketone. After the ink is removed and the screen image is not to be reused, the emulsion which blocks the non-image areas must be removed. Emulsion remover is generally sprayed onto the screen, then brushed into its pores. Sometimes a brush is dipped into a container of remover, then "worked" into the screen. Typical emulsion removers contain sodium meta poriodate or a salt of periodic acid. After ink and emulsion have been removed, there is often a "ghost" image that remains on a screen. A "haze" remover chemical is applied to the affected areas. These are usually very caustic formulations typically containing potassium hydroxide and aliphatic ether alcohols.

72

: Appendix VIII. Sources for Assistance

A. Publication Sources on Pollution Prevention in the Printing Industry

Institute of Local Self Reliance 2425 18th Street, NW Washington, DC 20009 (202) 232-4108

North Carolina Department of Human Resources Solid and Hazardous Waste Management Branch PO. Box 2091 Raleigh, NC 27602 (919) 733-2178

North Carolina State University Industrial Extension Service Raleigh, NC 27695-7902 (919) 737-2303

United States EPA Small Business Ombudsman 401 M Street, SW (A-149C) Washington, DC 20460 (800) 368-5888

United States EPA Center for Environmental Research Information Publication Office 26 Martin Luther King Drive Cincinnati, OH 45268 (513) 569-7562

Waste Redudion Resource Center 3825 Barrett Drive, Suite 300 PO. Box 27687 Raleigh, NC 27611-7687 (800) 476-8686

73

APPENDlX VIII. SOURCES FOR ASSISANCE

Follution Prevention Clearing House U.S. P A (202) 260-1023

Minnesota Technical Assistance Program (MnTAP) University of Minnesota PO. Box 197 Mayo 420 Delaware Street SE Minneapolis, MN 55455 (612) 625-4949

North Carolina Pollution Prevention Pays Program Department of Natural Resources and Community Development PO. Box 27687 512 North Salisbury Street Raleigh, NC 27611 (919) 733-7015

B. Agencies Providing No Cost, Hands-on Technical Assistance

The University of Tennessee Center for Industrial Services 226 Capitol Boulevard Bldg., Suite 606 Nashville, TN 37219 (615) 532-8657

Waste Reduction Resource Center 3825 Barrett Drive, Suite 300 PO. Box 27687 Raleigh, NC 27611-7687 (800) 476-8686

Tennessee Department of Environment and Conservation Small Business Assistance Program 8th Floor, L & C Annex 401 Church Street Nashville, TN 37243-1551 (800) 734-3619

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APPENDIX VIII. !30URCES FOR ASSISTANCE

C. National Printers and Graphic Arts Associations

Technical Association of the Graphic Arts PO. Box 3064, Federal Station Rochester, NY 14614 (416) 475-6662

American Institute of Graphic Arts 1059 Third Avenue New York, NY 10021 (212) 752-0813

National Association of Printers and Lithographers 780 Palisades Avenue Teaneck, NJ 07666 201-342-0700

Graphic Arts Technical Foundation 4615 Forbes Avenue Pittsburgh, PA 15213 (312) 621-6941

International Association of Photoplatemakers 552 W. 167 Street South Holland, IL 60473 (312) 596-5111

National Association of Printing Ink Manufacturers 550 Mamaroneck Avenue Harrison, NY 10528 (914) 698-1004

Printing Industries of America, Inc. 100 Daingerfield Road Alexandria, Virginia 22314 (7O3)519-8100

75

APPENDIX VIII. SOURCES FOR AssI!3 'M"

Printing Industry Association of the South 305 Plus Park Boulevard Nashville, TN 37217 (61 5)366- 1094

76

: Appendix IX. Selected Equipment Vendors and Printing Industry Chemical Suppliers :

Suppliers of Photoprocessing Chemicals and Films

NCR, Media Products Division PO. Box 660 Humbolt, TN 38343-2642 (901) 784-5330

Best Graphic System, Inc. 1160 N. Barfield Road Murfreesborq TN 37133-0957 (615) 893-2378

Coppinger Color Lab, Inc. 1525 Hardeman Lane Cleveland, TN 37311-5845 (615) 479-5426

Suppliers of Plates, Processing Chemicals, and Platemaking Equipment

IBF Corporation 44 Plauderville Avenue Garfield, NJ 07026-0278

Litho Carton Service, Inc. 2109 Thomas Road Bartlett, TN 38134-5615

(800) 423-3456 (901) 372-9231

Suppliers of Printing Inks

American Printing Ink 4745 Adams Road Hixson, TN 37343-4001 (615) 875-4705

Flint Ink Cop. 3726 Air Park Memphis, TN 38118-6006 (901) 363-0441

KOHL-Madden Printing Ink Corp. 406 Harding Industrial Drive Nashville, TN 37211-3183 (615) 331-4300

Flint Ink Corp. 501 Davidson Street Nashville, TN 37213-1413 (615) 255-3103

IC1 Specialty Inks 3730 Old Tasso Road Cleveland, TN 37312-572 (615) 479-9871

77

APPENDIX IX. SELECTU) EQUIPMENT VENDORS AND NDUSTRY CHEMICAL SupwUiS

Vendors Cleaning Equipment and Chemicals

Amax Industrial Products Div. 960 S. Third Street Louisville, KY 40203 (800) 662-0023

EZE Products Inc. PO. Box 5744 Greeneville, SC 29606 (800) 435-0444

Vendors of Explosion Proof Centrifuges

Doyle, J.E. Co. The PO. Drawer 4370-T Akron, OH 44321

International Specialty Products 1361 Alps Road Wayne, NJ 07470

Quality Solids Separation Co. TEMA Systems, Inc. Humbolt Decanter Inc. : PO. Box 920776-T 7806 Pedsky Drive 3200 Pointe Parkway *

Houston, TX 77292-0776 Dept. MTM Dept. S-1 Cincinnati, OH 45249 Atlanta, Georgia 30092 (800) 766-0680 (404) 448-4748

Vendors of Solvent Distillation Equipment

W A Corporation Process Division PO.. Box 16348 Charlotte, NC 28297

Eaton Corp. Process Control Components 1199 S. Chilocothe Rd. Auroa, OH 44(202)

Brighton Corporation 11861 Mosteller Road Cincinnati, OH 45241

Crest Ultrasonic Corp. Scotch Road Mercer County Airport Trenton, NJ 08628

Gold and Silver Refiners and Dealers Bowden Industries INC. PO. Box 913 Covington, TN 38019-0913

Capital Silver Service, lnc. 310 S. Water Street. Gallatin, TN 37066

(901) 476-1813 (615) 452-3574

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