Division of Pollution Division of Pollution Prevention and Prevention and Environmental Environmental

AssistanceAssistance

Industrial Assistance SectionIndustrial Assistance Section

John Burke 336-249-1480John Burke 336-249-1480

www.p2pays.org

On-site Technical AssistanceOn-site Technical Assistance

FreeFree Non-regulatoryNon-regulatory Multimedia (air / water / solid waste)Multimedia (air / water / solid waste) Areas of assistance Areas of assistance

– Achieving compliance Achieving compliance – Reducing waste management costsReducing waste management costs– Increasing production efficiencyIncreasing production efficiency– Developing environmental management Developing environmental management

systemssystems

Conducting a Solid Waste Conducting a Solid Waste Reduction AssessmentReduction Assessment

http://www.p2pays.org/ref/01/00833.pdfhttp://www.p2pays.org/ref/01/00833.pdf

Section 3 page 65Section 3 page 65

StepsSteps

PreparationPreparation Opening meetingOpening meeting Walk throughWalk through Closing meetingClosing meeting Final reportFinal report Follow-upFollow-up

Assessment PreparationAssessment Preparation

Obtain summary informationObtain summary information– What company does and major solid waste What company does and major solid waste

issuesissues Request attendees for opening meetingRequest attendees for opening meeting

– Environmental manager, production Environmental manager, production manager, and maintenance managermanager, and maintenance manager

Background research on industryBackground research on industry– Online research (p2pays.org references) Online research (p2pays.org references)

Background InformationBackground Information

Monthly tonnageMonthly tonnage Monthly tipping feeMonthly tipping fee Monthly hauling feeMonthly hauling fee Monthly rental feeMonthly rental fee Solid waste containersSolid waste containers

– #, size, and average tonnage#, size, and average tonnage Labor costs (waste handling)Labor costs (waste handling) Current recycling/reuse program dataCurrent recycling/reuse program data Scrap rates and purchasing dataScrap rates and purchasing data

Fiber Glass Pipe

Disposal3%

Labor11%

Material86%

Cost of Waste$1.443 million a year

Waste Management HierarchyWaste Management Hierarchy

SourceReduction

Direct Reuse

On-site Recycling

Off-site RecyclingTreatment & Disposal

Assessment PreparationAssessment Preparation

Obtain summary informationObtain summary information– What company does and major solid waste What company does and major solid waste

issuesissues Request attendees for opening meetingRequest attendees for opening meeting

– Environmental manager, production Environmental manager, production manager, and maintenance managermanager, and maintenance manager

Background research on industryBackground research on industry– Online research (p2pays.org references) Online research (p2pays.org references)

Opening MeetingOpening Meeting

Facility layout and operations overviewFacility layout and operations overview Current recycling programs and solid waste Current recycling programs and solid waste

management programsmanagement programs– Is there a waste reduction team or other team?Is there a waste reduction team or other team?– How are employees trained and informed?How are employees trained and informed?– Is there an employee suggestion program?Is there an employee suggestion program?– Are there goals established?Are there goals established?

Review of cost dataReview of cost data New projects or failed projects related to waste New projects or failed projects related to waste

reductionreduction

Walk ThroughWalk Through

Consider starting out with “dumpster Consider starting out with “dumpster dive” and tour of recycling area.dive” and tour of recycling area.

Follow flow of material through Follow flow of material through production from receiving to shipping.production from receiving to shipping.

Request supervisor of department to Request supervisor of department to provide overview.provide overview.

Approach employees for specific areas Approach employees for specific areas where waste are generated or handled.where waste are generated or handled.

Look in recycling and disposal containers Look in recycling and disposal containers

Walk ThroughWalk Through

Consider starting out with “dumpster Consider starting out with “dumpster dive” and tour of recycling area.dive” and tour of recycling area.

Follow flow of material through Follow flow of material through production from receiving to shipping.production from receiving to shipping.

Request supervisor of department to Request supervisor of department to provide overview.provide overview.

Approach employees for specific areas Approach employees for specific areas where waste are generated or handled.where waste are generated or handled.

Look in recycling and disposal containers Look in recycling and disposal containers

Material Receiving / Storage / Material Receiving / Storage / ShippingShipping

Practices that cause damage or spoilagePractices that cause damage or spoilage Opportunities for to reduce, reuse or Opportunities for to reduce, reuse or

recycle packagingrecycle packaging– Packaging redesignPackaging redesign– Bulk containers for high use materialsBulk containers for high use materials– Reuse of pallets, boxes, sacs for in plant Reuse of pallets, boxes, sacs for in plant

distribution or shippingdistribution or shipping– Packaging return programsPackaging return programs

Case StudyCase Study

Packaging redesignPackaging redesign– Company: Company: Eagle Snacks, RobersonvilleEagle Snacks, Robersonville– Product: Product: snack foods (potato ships, nuts)snack foods (potato ships, nuts)– Problem: Problem: costs for packaging materialscosts for packaging materials– Solution: Solution: reduce layers of bags from 5 to 3reduce layers of bags from 5 to 3

reduce thickness of steel cansreduce thickness of steel cans– Savings:Savings: 500 tons / yr of plastic500 tons / yr of plastic

225 tons / yr of steel225 tons / yr of steel

Material Receiving / Storage / Material Receiving / Storage / ShippingShipping

Practices that cause damage or spoilagePractices that cause damage or spoilage Opportunities for to reduce, reuse or Opportunities for to reduce, reuse or

recycle packagingrecycle packaging– Packaging redesignPackaging redesign– Bulk containers for high use materialsBulk containers for high use materials– Reuse of pallets, boxes, sacs for in plant Reuse of pallets, boxes, sacs for in plant

distribution or shippingdistribution or shipping– Packaging return programsPackaging return programs

ProductionProduction

Waste generated from start-up, shut down, Waste generated from start-up, shut down, change-over.change-over.

Waste generated from continuous operations Waste generated from continuous operations edge trim, machining, etc.edge trim, machining, etc.

Locations and labeling of recycling containers.Locations and labeling of recycling containers. Handling of off-spec materialsHandling of off-spec materials Monitoring of waste volumes (80/20 rule)Monitoring of waste volumes (80/20 rule) Identify “True Cost of Wasting”Identify “True Cost of Wasting”

Case StudyCase Study

Production wasteProduction waste– Company:Company: Synthetic paper manufacturerSynthetic paper manufacturer

– Problem:Problem: 1.4 M lbs of product waste / yr1.4 M lbs of product waste / yr

– Causes:Causes: Poor training, operational Poor training, operational controlcontrol

- Savings:- Savings: Revenue increases of +150,000/yr Revenue increases of +150,000/yr for for 25% reduction in wasting25% reduction in wasting

Wasted Synthetic Papersetting blades

coat

ing

start-up

roll too tightwavy paper

transp

ort

damaged surfacedamaged ends

light paper jammingstacking

ProductionProduction

Waste generated from start-up, shut down, Waste generated from start-up, shut down, change-over.change-over.

Waste generated from continuous operations Waste generated from continuous operations edge trim, machining, etc.edge trim, machining, etc.

Locations and labeling of recycling containers.Locations and labeling of recycling containers. Handling of off-spec materialsHandling of off-spec materials Monitoring of waste volumes (80/20 rule)Monitoring of waste volumes (80/20 rule) Identify “True Cost of Wasting”Identify “True Cost of Wasting”

The Cost of WasteThe Cost of Waste

Raw MaterialRaw Material LaborLabor DisposalDisposal Waste HandlingWaste Handling

– PhysicalPhysical– AdministrativeAdministrative

Truck Liner ManufacturerTruck Liner Manufacturer

PlasticSheet

Oven

Carpet

Parts

Waste

Press

Rooney, Charles “Economics of P2: How Waste Reduction Pays”. Pollution Prevention Review, Summer 1993

4.86 pounds2% loss allowance4.96 pounds - 2 parts0.10 pounds waste

2.30 pounds 2.66 pounds

Pressed Plastic PartsPressed Plastic Parts

Material93.5%

Disposal3.5%

Labor3%

4.30 million/yr

Cost of Waste

2.75 million/yr

Cost of Plant Labor

Rooney, Charles “Economics of P2: How Waste Reduction Pays”. Pollution Prevention Review, Summer 1993

Other AreasOther Areas

Cafeteria/break roomsCafeteria/break rooms– Food waste handlingFood waste handling– UtensilsUtensils– Recycling containersRecycling containers

Office AreasOffice Areas– Purchasing specificationsPurchasing specifications– Recycling containersRecycling containers

Other AreasOther Areas

DisposalDisposal LaboratoryLaboratory Production maintenanceProduction maintenance Vehicle maintenanceVehicle maintenance Quality control / assuranceQuality control / assurance Utilities (boilers, compressors)Utilities (boilers, compressors) Bag housesBag houses Waste treatmentWaste treatment

Closing MeetingClosing Meeting

Praise existing programs and efforts at Praise existing programs and efforts at waste reduction.waste reduction.

Discuss areas where the team sees Discuss areas where the team sees potential for improvements potential for improvements opportunities.opportunities.

Request additional information that will Request additional information that will be required to develop report.be required to develop report.

Final ReportFinal Report

Provide description of operationsProvide description of operations Develop best estimate of waste stream Develop best estimate of waste stream

analysis and associated costanalysis and associated cost Develop true cost estimates for selected Develop true cost estimates for selected

waste streamswaste streams Discuss technologies and techniques for Discuss technologies and techniques for

reducing or reusing waste streamsreducing or reusing waste streams Provide listing of markets for recycled Provide listing of markets for recycled

materialsmaterials

Waste Estimated Total Volume

Entering Plant,

lbs/year

Estimated Material

Wasted, %

Estimated Volume of Material

Landfilled, lbs/year

Estimated Disposal

Costs, $/year

Estimated Material

Costs, $/year

Straps (suppliers) 13,000 100% 13,000 $569 ?Straps (sister facilities) 15,000 100% 15,000 $656 ?Bale Wraps 26,500 10% 2,650 $116 ?Poly Bags (25 cents/lb) 23,548 100% 23,548 $1,030 $5,887Sleeving 20,000 100% 20,000 $875 $30,000Plastic Sheeting 11,804 100% 11,804 $516 $6,900Cardboard (from suppliers) 1,250,000 15% 187,500 $8,203 ?Disposable Dye Springs 800,000 2% 16,000 $700 ?Wasted Fiber, Virgin 1,000,000 2% 20,000 $875 ?Wasted Fiber, Dyed 500,000 2% 10,000 $438 ?Pallets*** 88,000 $3,850 ?Demolition (equipment/buildings)** 66,880 $2,926 ?Packaging material Kraft Paper 28,000 20% 5,600 $245 $2,600 Paper Board Dividers 205,360 10% 20,536 $898 $9,700 Paper Cones (0.05 lbs/cone) 1,450,000 2% 29,000 $1,269 $1,700 Wax 169,544 20% 33,909 $1,484 $46,000 Cardboard (for packaging) ?? 1% ? ? ?

Total 563,427 $24,650 $102,787Estimated Total Landfilled* 1,760,000 $77,000

Improve winding Improve winding operation to reduce operation to reduce wasted fiber through wasted fiber through training and awareness training and awareness or increased automation.or increased automation.

Yarn, lbs/day 500,000Total Wasted, %

2%

Usable Portion of Wasted Yarn, %

5%

Value of Product Yarn, $/lb

$ 1.50

Value of Wasted Yarn, $/lb

$ 0.25

Estimated lost value, $/year

$ 162,500.00

Waste Estimated Total Volume

Entering Plant,

lbs/year

Estimated Material

Wasted, %

Estimated Volume of Material

Landfilled, lbs/year

Estimated Disposal

Costs, $/year

Estimated Material

Costs, $/year

Straps (suppliers) 13,000 100% 13,000 $569 ?Straps (sister facilities) 15,000 100% 15,000 $656 ?Bale Wraps 26,500 10% 2,650 $116 ?Poly Bags (25 cents/lb) 23,548 100% 23,548 $1,030 $5,887Sleeving 20,000 100% 20,000 $875 $30,000Plastic Sheeting 11,804 100% 11,804 $516 $6,900Cardboard (from suppliers) 1,250,000 15% 187,500 $8,203 ?Disposable Dye Springs 800,000 2% 16,000 $700 ?Wasted Fiber, Virgin 1,000,000 2% 20,000 $875 ?Wasted Fiber, Dyed 500,000 2% 10,000 $438 ?Pallets*** 88,000 $3,850 ?Demolition (equipment/buildings)** 66,880 $2,926 ?Packaging material Kraft Paper 28,000 20% 5,600 $245 $2,600 Paper Board Dividers 205,360 10% 20,536 $898 $9,700 Paper Cones (0.05 lbs/cone) 1,450,000 2% 29,000 $1,269 $1,700 Wax 169,544 20% 33,909 $1,484 $46,000 Cardboard (for packaging) ?? 1% ? ? ?

Total 563,427 $24,650 $102,787Estimated Total Landfilled* 1,760,000 $77,000

Reduce Reduce processing aids processing aids through through process process modifications modifications and increased and increased controlscontrols

Current Wax Disc

2

1

New Wax Disc

3

2

SteelfabSteelfab

Fabricates and coats structural steelFabricates and coats structural steel Potential liability and new air permits Potential liability and new air permits Reduced coatings by 50% and used three Reduced coatings by 50% and used three

coatings on 95% of orderscoatings on 95% of orders Trained estimating engineers and Trained estimating engineers and

purchasing agents on benefits of using purchasing agents on benefits of using selected coating systems.selected coating systems.

Required approval of environmental Required approval of environmental personnel prior to issuing bidpersonnel prior to issuing bid

SteelfabSteelfab

Reduce VOC/HAP emissionsReduce VOC/HAP emissions Reduce coating system change-outs /cleanupReduce coating system change-outs /cleanup Reduce use of MEK Reduce use of MEK Reduce production time and man-hoursReduce production time and man-hours Reduce training requirements for paintersReduce training requirements for painters Reduce purchasing requirements and problems Reduce purchasing requirements and problems

dealing with multiple coating suppliersdealing with multiple coating suppliers Lower total contract costs to customersLower total contract costs to customers