1992 Governors's Awards For Excellence

in Waste .Management

Resented April 22,1993

State of North Carolina James B. Hunt, Jr., Governor

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Department State of North Carolina

of Environment, Health, and Natural Resources Cavemor's Waste Management Board

James B. Hunt, Jr.. Govanor Jonathan B. Howts. Secretary

The Governor's Awards for Excellence for Outstanding Achievement in Waste Management

For the past 11 years, the Governor's Waste Management Board has administered the Governor's Awards for Excellence in Waste Management to qualifving North Carolina businesses and Utitutes.

or industrial waste who have shown outstanding commitment to protecting the environment and public health through superior waste management practices. These practices include source reduction, reuse, recycling, resource recovery, and pollution prevention measures. This is the f h t year that the competition has included an industrial waste category. This category was added because many businesses have done an outstanding job of managing these wastes.

environmental and economic benefits, technological innovation, commitment by management. and leadership in communicating awareness to others.

The awards program honors generators of hazardous, low-level radioactive,

The criteria for judging entries for the awards program include

A panel of six judges, representing various interests, extensively reviews and recommends award recipients to the Governor's Waste Management Board and the Governor for approval.

The Board appreciates the support and participation of North C a r o h businesses and institutions in helping to make the awards program a continued success.

& ! ! -& Captain William H. Briner. Vice-Chairman

P.O. BDor 27687. Wd&, North 2761 1-7687 Teltphonc 919-733-9020 FAX 919-733-9020 An Equal 0ppo-Q Affirmathe Actlon Employer

Panel of Judges

ReDresentinl the Gove mor's Waste Manap ement Board

Dr. James K Ferrell North Carolina State University

Raleigh, North Carolina

ReDresentiIU Xndustrrr IReciDients of the 1991 Govemor's Awards for

Excellence in Waste Mananementl

Ms. Pat Gobble Thomson Crown Wood Products

Mocksville, North Carolina

Mr. Doug Johnson IBM Corporation

Charlotte, North Carolina

ReDresentinP the Gened Public with an Interest in the Environment

Ms. Betsy McCrodden NC League of Women Voters

Raleigh, North Carolina

Mr. Jim Boweman Anson County-Environmental Affairs Board

Wadesboro, North Carolina

ReDresentiW Higher Education. Research. or Technology

Dr. Wayne Thomann Duke University

Durham. North Carolina

1992

Governor’s A d for Excellence

For Outstanding Achievement in Hazardous Waste Management

Presented

April22,1993

To

Glaxo Glaxo Inc. Zebulon, North Carolina

Glaxo Inc. Zebulon, North Carolina

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-0's manufacturing operation in Zebulon formulates raw materials and pharmaceutical actives into their anal pharmaceutical product fonn.

In 1987, Glaxo initiated a project to find an alternative coating process for its largest selling product, Zantac. Zantac (ranitidine hydrochloride) is used to treat duodenal and gastric ulcers and heartburn by reducing gastric acid secretions in the stomach. A protective coating is added to the tablet to increase its stability and ease of swallowing. To achieve this level of stability and integrity, Glaxo used a mixture of organic solvents to apply the film coating. This created a hazardous waste by-product.

AaueousCoatineProcess Glaxo selected a non-hazardous water-based solution to replace organic

solvents used in applying the protective coating. This process change was very unique because ranitidine is soluble in water and readily degradable in extreme heat and moisture.

. In order to implement this process. Glaxo had to make extensive changes to its coater spray assemblies and revamp the coater air handling systems including the installation of larger fans, heating coils, and dehumidifiers. Upgrade costs totaled $1.5 million.

Without altering product quality, Gkxo completely eliminated solvent emissions and occupational exposure as well as the problems encountered when hamrdous waste is generated and stored on-site.

Over 400 tons of hazardous waste and 7.5 tons of air emissions were generated annually before implementing this process. Now Glaxo has zero air emissions and zero hazardous waste generation from this process. This new water- based solution is non-hazardous and can be discharged directly into the sanitary sewer.

G k o saved more than $286,000 in material and $322,900 in disposal costs with a three-year payback period.

Ghxo has implemented this new technology at its other facilities worldwide and was highlighted by the International Chamber of Commerce at the United Nations Commission on Environment and Development (UNCED) "Earth Summit" in Rio de Janeiro. Brazil in June 1992. Glaxo's commitment to preselving and protecting public health and the environment extends to its community involvement activities. It is a major contributor to several educational institutions and charities in North Carohm and across the United States.

Contact: Laura Long, Environmental Safety Engineer (919) 269-1592

1992

Governor's Award for Excellence

For Outstanding Achievement in Hazardous Waste Management

Presented

Aprll22,1993

To

Northern Telecom Inc. Research Triangle Park; North Carolina

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Northern Telecom Inc. Research Triangle Park, North Carolina

Northern Telecom Inc. is a global manufacturer of fully digital telecommunications switching equipment. In North Carolina, the company manufkctures. sells. and services digital telecommunications systems for the public telephone network. Northern Telecom and BNR the company's research and development subsidiary, employ more than 8.000 people in North Carolina.

In 1988. Northem Telecom pledged to completely phase out ozone depleting CFC- 113 (chlorofluorocarbons) from all of its 55 manufacturing and research operations worldwide within three years. It became the first global telecommunications company to do so ahead of ~ t i ~ d and international schedules. To accomplish this, Northem Telecom developed a new process that eliminates the cleaning step in the manufacturing of printed circuit boards. In 1992 Northern Telecom experienced its first full year of being 100 percent "CFC free. " --

A synthetic flux applied to circuit boards to aid the soldering process, left a sticky residue on the circuit boards. The residue had to be cleaned from the board since it could collect dirt and moisture and result in equipment failure. Cleaning required the use of chlorinated solvents such as CFC-113. Northern Telecom engineers worked with vendors to develop a new thinner "low-solids" flux and implemented a new spray misting technology which applied less flux to the boards. These changes eliminated the cleaning requirement for Northern Telecom and any other companies that adopt the new technology without harming product quality.

Northern Telecom more than $4 million to date, and the new "no clean" process begun in the fall of 1988 will save more than $50 million over its first eight years.

plants in North Carolina reported 265.000 pounds of CFC-113 released as fugitive air emissions. CFC hazardous waste generated was reported as 42,000 pounds. In 1991, after the "no-clean" processes had been implemented, Northern Telecom used no CFC-113, reducing total hazardous waste generated by 65 percent.

The elimination of CFC- 113 from the manufacturing processes has saved

In 1989, before the implementation of this project, Northern Telecom

Northern Telecom has readily shared its "no-clean" knowledge with the industrial community and countries throughout the world. By helping to develop a new technology which eliminates the use of chlorofluorocarbon solvents. less chlorinated hazardous waste will be generated by manufacturing companies using this process and far fewer solvents will be emitted into the earth's atmosphere.

Contact: Douglas Slagel, Environmental Specialist 9 19-992-5 108

r

1992

Governor's Award for Excellence

For Outstanding Achievement in Industrial Waste Management

Presented

April22.1993

To fi=i

T H E

Hawey Mansion. R E S T A U R A N T & L O U N G E

Ziittel, Inc. The Harvey Mansion

Restaurant and Lounge New Bern, North Carolina

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ziittel, Inc. The Harvey Mansion Restaurant and LOunge

New Bern, North Carolina The Xarvey Manalon in New Bern is a h e dining restaurant and lounge

located in an unusually large and elegant finished house. The Mansion was built in 1804 and has quite an interesting past. It was used as a Boarding House in the late 1800s: a dormitory for the New Bem Academy; and classrooms for Craven Technical Institute (now Craven Community College). After being listed on the National Register of Historic Places in 1971, the Harvey Mansion ms restored and operated as a restaurant and lounge. Carolyn and Chef Beat Ziittel assumed ownership in 1991 and began a very aggressive recycling program.

m o r to implementing its recycling program, the Hatvey Mansion had M y garbage pickup from its eight cubic yard dumpster which resulted in a monthly fee of $304. Craven Countyhad just initiated its county-wide recycling program when the Ziittels assumed ownership and found this an exciting challenge.

The Ziittels fist founda farmer willing to accept their frozen compost, vegetable peelings, seafood and other meat scraps for animal food and fertilizer. Then staff was trained and retrained on their recycling program. Two containers were added to every station for food waste. One container is for compostable materials and the other for dry or packaging waste. Cardboard and other recyclable materials such as @ass are stored in special receptacles for recycling. These receptacles are provided by American Refuse Systems, Inc.

As a result, the Ziittels reduced trash pickups from daily to weekly and decreased the container size from eight to four cubic yards. This is about 3,000 cubic yards reduction per year of garbage collection. A n n d disposal costs dropped fiom $3,646 to $1,005.

The Ziittels are a ’mom and pop” operation committed to reducing waste. The couple moved to North Carolina from Switzerland where recycling efforts are extremely sophisticated. They have welcomed the opportunity to promote recycling and environmental awareness at the Hatvey Mansion.

Contact: Carolyn Ziittel, Co-owner 9 19-638-3205

1992

Governor’s Award for Excellence

For Sigdflcant Achievement in Industrial Waste Management

Presented

April22,1993

To

h1 SPINNING CORP.

Amital Spinning Corp. New Bern, North Carolina

Amital spinning corp. New Bern, North Carolina

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Amital Spinning Corp., located in New Bern, produces package custom-dyed high bulk acrylic yarn for the textile industry. It employs 345 people.

Through a water conservation and reuse program, Amital Spinning was able to reduce the amount of wastewater generated per pound of yarn dyed from 19.34 gallons in 1988 to 3.29 gallons in 1991. Wastewater volume was reduced from 320,000 gallons per day to 92,000 gallons per day while production increased from 12 to more than 20 dye batches of yam per day.

Water reuse began by collecting non-contact cooling water to be used in the color kitchen for the preparation of dye liquors. The use of this water allows the dye liquors to be prepared hot (80°F), reducing steam requirements during dyeing. The process water is then reused as production requirements will allow. Process water is recovered and the expended chemicals are replenished. .

Along with water and energy use reduction, Amital Sp- is saving about $45 per batch in chemicals and reducing the time required for heating by 8 to 10 minutes per cycle. Cost savings from January 1991 through December 1991 amounted to $2 10,000 for water use reduction and $52 1.100 for energy use reduction.

Amital Spinning also increased its profitability by more than $300.000 in 1991 through a solid waste recycling and reuse program. Income from recycle sales was nearly $90.000 and more than $20.000 was avoided in disposal costs. Much of the $300.000 ($192,600) is income from a waste product that is now being recycled into a first quality product. The company currently reprocesses approximately 242,000 pounds per year with this program.

Amital Spinning's total savings in 1991 for solid waste, water use reduction.

The company is committed to being a good industrial neighbor. This

and energy use reduction amounted to $1,034,448.

commitment prompted Craven County to invite Amital Spinning to be represented on the county's Commercial Recycling Sub-committee. The company has shared valuable information with others in the community with similar recycling and waste reduction problems.

Contact: James Ipock, Plant Engineer 919-636-3435

I case studies

Achievements inwaste ManagemCpf

Other entries in the 1992 awards program also demonstrated signillcant contributions to North Carolina’s pollution prevention and waste reduction ef€orts. Several were selected for recognition as case studies. These case studies. summarized from the 1992 entries, show how other companies developed cost effective strategies and sohtions to handle waste management problems.

The Ingersoll-Rand Portable Compressor Division In Mocksville manufactures portable air compressors, portable generators, and light towers. The finish painting of this equipment resulted in the production of hazardous waste and the release of volatile organic compounds (VOCs). Determined to reduce its waste generation, Ingersoll-Rand looked into alternative fhishing processes.

In the previous fhishing system, the parts were prime painted with an epoxy ester prime paint, assembled into the complete machine. and then Wsh painted with an enamel high gloss k i s h paint. InQersoll-Rand’s new finishing line uses a water-based Electrodeposition (E-coat) Prlme Paint System followed by a Powder paint Finishing System. Because of this change, the equipment must be =sembled after the finishing paint has been applied. This required several changes in the way the equipment was assembled, but an improvement in quality

seen with the new process. The change also had a drastic impact on waste generation. VOC emissions and hazardous waste generation were reduced 75 percent by replacing the solvent based paint system with the powder paint system. The project had a payback period of three years.

HARRIET & HENDERSON YARNS, INC.

sold to hosiery and outerwear knitters and weavers. The organic wastes from the cotton spinning process traditionally have been sent to the county landfill. By separating the wastes in the plant, Harriet & Henderson has been able to find alternative uses for all of the waste stream.

With partial funding fiom the N.C. Pollution Prevention Program and help from the North Carolha State University Agriculture Extension Service and Vance County Government, the company developed and implemented a process where some of the waste could be used as cattle feed. The separation also allowed the portion unacceptable for cattle feed to be captured and fed into other textile processes. The cattle feed, which is equivalent to a low grade hay, requires no extra machinery or processing by the farmer.

2,900 cubic yards of waste per year from the landfill. In addition, the company recycles parts of every stream of incoming packaging material.

Harriet & HendemnYaxno in Henderson spins cotton that fs eventually

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Harriet & Henderson has reduced cost by $25,285 and diverts more than

Crown

MITSUBISHI SEMICONDUCTOR AMERICA INC.

Mitsubishi Semiconductor America Inc. (MSAI) in Durham is a manufacturer of high quality dynamic memory devices. The production of these devices requires a very water intensive process. To reduce water use and waste water production, MSAl instituted two major projects.

automatically shutoff the water flow to these benches. Resistivity meters are now also being used to divert reusable water for recycling. The second project recycles rinse water from the deionization column regeneration process back to the columns once the rinse water has reached a specified resistivity. By installing these two projects, MSAI was able to reduce monthly water consumption from 10.5 million gallons to 8.4 million gallons. The total project cost was $40,000, but annual savings in water, waste water treatment, and neutralization costs is roughly $250,000. MSAI has also begun using processed waste water to wash its chemical process containers so they can be crushed and recycled.

The first project involved installing timers on process wet benches that

RJ. Reynolds Tobacco Company has cigarette manufacturing facilities in Winston-Salem and Forsyth County. In 1991, the company joined forces with Waste Management, Inc. (WMI) to establish one of the largest privately funded materials recovery facilities (MRF) in the southeast. RIR delivers clean waste rilated to the manufacture of cigarettes to the MRF where WMI further separates and sells the material. Under their agreement, RJR pays the handling fees for the waste. and the revenues are shared according to their contract. Bemuse RJR's materials provide the foundation of the enterprise. WMI is able to serve neighboring businesses and small communities whose waste streams would otherwise be uneconomical to handle. WMI has separate contractual relationships with the other parties. Besides providing a recycling outlet to businesses and neighboring communities, the MRF has helped RJR reduce their solid waste going to the landfill by 52 percent since the 1988- 1989 flscal year. The cost savings have also been substantial. RIR received $686.000 in revenues from sales of its recyclable matexials in 1992.

MASTERCRAFT

The Mastercraft Fabrics Diddon of Collins & Aikman Corporation is a jacquard weaver of home furnishings and contract fabrics with five locations in North Carom Through recycling and reuse, Mastercraft has been able to reduce many of the traditional solid waste streams found in the textiles industty.

latex used in backing to its raw form for re-use in non-critical applications, re-use of paper yarn carriers previously disposed of fn the landm, and concentrated ef€orts to make optimum use of IZIW materials by focusing on fabric yields. Allyam and fabric wastes are sold for further processing into useable products. B, reducing landfill wastes, Mastercraft has realized savings of approximately $300,000 at its &re North Carolina facilities.

Examples of Mastercraft'r recycling efforts include the breaking down of

. JOHNSON & JOHNSON ADVANCED MATEFUAIS COMPANY

J&J Advanced Materials Company in Benson manufactures non-woven textiles and fabrics for medical markets. wiping markets, and the automotive industry. The company is not only working to minimize its current waste streams. but has found a way to address hture wastes before they occur. It adopted a Product/Rocess Development Rogram which requires an environmental impact assessment of all new products and processes. The product assessments or life cycle analyses examine the environmental impact and the natural resource usage assodated with a product from its inception at the raw material stage to its final disposition as waste. This allows J&J Mvanced bSatedab to determine what processes are truly the least detrimental to the environment. Current waste " k a t i o n efforts in recycling have saved nearly 1.6 million pounds of office, packaging, and production waste from going to the landiI3.l. The company's efforts saved it more than $365,000 in 1992.

=MET ELECTRONICS CORPORATION

Xemet Electronics Coxpoxation in Shelby manufactures ceramic capacitors used in the electronics industry. The waste streams from this operation consist mainly of metals and organic solvents used in cleaning operations. One of these solvents is methylene chloride, a halogenated solvent that is targeted for elimination by the Montreal Protocol. Kemet eliminated its use of the solvent by switching to an aqueous cleaner. Another solvent used at the facility for cleaning is tbluene. m e t has been able to reclaim and reuse this solvent by blending it with fresh toluene. Reusing the solvent has reduced the amount of hazardous waste sent off-site by 12,129 pounds per year.

Lead-bearing scrap from the production of capacitors had traditionally been sent to a l a n u . The facility is currently shipping this waste to a metal reclaimer. Having the metal reclaimed reduced lead contaminated hazardous waste by 29,330 pounds. During 1992, waste minimization projects at Kcmet resulted in savings of $28,475 and a reduction of hazardous waste by 155,229 pounds.

BLACK & DECKER INC.

Black & Decker in Fayetteville manufactures power tools and accessories for consumer and industrial markets. As part ofa company wide comprehensive waste management plan, the Fayetteville faciltty invested $144,000 to reduce its wastes. A semi-automatic dtra ffltration system was installed to process oil contaminated water from various waste streams. Aqueous cleaners are replacing the petroleum naphtha parts washers, and a system to recycle cutting oils on site was purchased. Black & Decker has also begun dewatering its grinding sludge, reducing the need for stabilization with sand prior to landm disposal. Although these projects seem large and costly, they have been very cost effective. Black & Decker has saved $139,000, and has reduced non-hazardous waste by 844,000 pounds per year. Other recycling efforts and standardization of pallets has helped reduce its landfill load by approximately 4.56 million pounds.

ALLIED-SIGNAL, mC.

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Allied-Signal, Inc. in Moncure manufactures high strength polyester yarn for use in products such as automobile tires. seat belts, conveyor belts, cordage and broad woven fabrics such as tarps. AlUed-Signal set a plant goal to eliminate all forms of waste polyester from disposal at the county landfill. To achieve this goal, AlliedSignal organized a team of employees from various departments to identi@ waste polyester management projects and to set goals for completing the projects.

After iden-g all the waste streams. the team members decided on Several steps to be taken. The &st a d simplest step involved segregauon of polymer sample waste from routine trash collected in the department. This waste was then added to the polymer waste that was already being recycled. Recycling much of the waste was not economical due to the bulkiness of the material. To solve this problem, Allied-Signal purchased a grinder that would reduce the waste to chips that could be easily boxed for shipment to recyclers. Allied-Signal has achieved its goal to eliminate at least 99 percent of waste polyester from disposal at the county l a n u .

The Governor's Waste Management Board advises the Governor and General Assembly on the development and operation of safe and effective waste management programs for North Carolina.

Dr. JamesK Fmell Raleigh, NC

m"z Dou$as story Greenville. NC

David A Craft Canton NC

General Pub lie With An Interest in - Dr. Martin P. Hines

Raleigh. NC

KathleenG. Moyer Wilson, NC

Dr. Harold A Ladwig Wilson. NC

Gretchen Peed Hickory. NC

Lynn wheeler Charlotte. NC

Dr. George Bradley Cherryvllle, NC

*

Lewis k Brandon, I11 Greensboro. NC

Ray Forrest Raleigh, NC

JonathanB. Howes Raleigh. NC

Paul Jordan Raleigh. NC

2 - m James Self Raleigh. NC

State of North Ca” JamesB. Hunt Jr., Governor

North Carolina Department of Environment, Health, and Natural Rtsourcts Jonathan B. Howes, Secretary

Governor’s Waste Management Board P.O. Bax 27687

Raleigh, North Carolina 27611-7687 9 19-733-9020

600 copies of- nport were prlnted at a cost d $222.60 or &371 per copy. PrLnted on recycled paper.