[South Carolina] Governor's Pollution Prevention Award -- 1998 Winners

Marine Corps Air Station

Beaufort, SC

Winner -- Large Sized Business or Industrial Facility

DESCRIPTION OF THE PROJECTS

The Marine Corps Air Station (MCAS) Beaufort, located in Beaufort, South Carolina, is home to seven—soon to be nine—F/A-18 Hornet aviation squadrons. The F/A-18 Hornet is one of our nation’s premier jet fighters. Roughly 4,000 military and civilian personnel are stationed aboard the Air Station. Its mission, in support of our nation’s defense, is to provide those services and personnel necessary to keep these aircraft combat-capable at all times, including their Marine contingent. The large amount of support materials, coupled with past practices, historically created considerable quantities of excess hazardous materials and associated hazardous waste. The problems and root causes, not being singular in nature, required a solution equally diverse. The following is a description of MCAS Beaufort’s comprehensive efforts to prevent pollution and to reduce the use of hazardous materials and generated amounts of hazardous waste.

Improved Material Management (CHRIMP) A major pollution prevention success story, and now a cornerstone in the Air Station’s P2 efforts, is its Consolidated Hazardous Materials Reutilization and Inventory Management Program (CHRIMP). Command-level support and a team approach were the critical components responsible for successful implementation of this program. Large quantities of hazardous materials are inherent with combat aircraft maintenance. Prior to CHRIMP, each squadron was essentially independent, procuring its own hazardous materials. This process resulted in inefficiencies, excessive storage, zero material reutilization, and substantial waste—all at increased costs.

That was the status quo in May of 1995. On February 1, 1996, starting with the squadrons, CHRIMP implementation began. No small feat by any means, this fundamental process change represented a radical departure from the way materials were previously procured and issued. Indeed, it included the collection of all excess hazardous materials, a significant accomplishment. To ensure their participation, the Commanding Officer for Marine Aircraft Group 31 directed excess hazardous materials—left behind by deploying squadrons—be collected and added to the CHRIMP inventory. The program now features three primary centralized issue points for hazardous materials called Haz Min centers. The material issue process to the individual user is now barcoded. Each container is serialized and tracked, and must be returned. This process includes the return of empty containers as well. Unused portions are reissued. Additionally, material is provided in the smallest, singular unit-of-issue possible. Users are typically restricted to possessing only a week’s worth of material at a time. This requirement prevents the past practices of overstocking and hoarding. Prior to CHRIMP, it was not uncommon to find hazardous materials older than the Marines using them. All empty metal containers are subsequently recycled.

Some of the tangible benefits realized since CHRIMP implementation are summarized as follows:

• Squadrons (the Air Station’s largest generator) have reduced their hazardous waste by 47 percent, while generating 3,124 fewer requisitions for hazardous materials.

• Material reutilization increased 100 percent.

• Improved access and availability of materials along with enhanced "safe" material-storage practices.

Part Cleaning Representing the largest single hazardous waste stream annually at the Air Station, part-cleaning operations were a prime target for improvement. Specifically, the part-washing machines utilized for cleaning—located in the aircraft and other maintenance areas—generated approximately 42,000 pounds of hazardous waste each year. In October of 1997, all part washers were replaced with a new type that recirculates and filters the solvent. This feature greatly prolongs the useful life of the solvent. The original solvent itself was also replaced with a less-hazardous alternative. Once the effectiveness of the solvent is depleted, it is changed out and then recycled. To date, an 80 percent reduction in this waste stream has been realized. As of July 1998, only 4,000 pounds of hazardous waste from part-washer operations have been generated.

Shop Rags Each year, approximately 11 tons of rags saturated with oil, grease, paint, etc., are collected and disposed of as either a hazardous or nonhazardous waste. Typically, this was the second-largest hazardous waste stream each year at the Air Station. In June of 1997, a shop towel recycling program was begun to abate this problem. Results have been dramatic. Thus far, a 65 percent reduction in this waste stream has been realized. Refinements are expected to yield even more reductions in the near future.

Material Substitution (Gerber Machine) Demodexing/modexing is a term used to describe the process whereby aircraft lettering and markings are first removed and then reapplied. The old method of paint removal and reapplication required extensive use of hazardous materials, was man-hour intensive, and generated between 2,000 and 4,000 pounds of hazardous waste annually. Furthermore, the paint drying time was excessive: multimillion dollar aircraft sat idle for one to three days to allow the painted surfaces to dry. Approximately forty to fifty aircraft go through this process each year.

Introduction of the Gerber® machine practically eliminates the use of paint in the demodexing/modexing process. It is an excellent example of source reduction. The new Gerber process employs a self-adhesive vinyl film that is stenciled automatically from data or logo designs entered into a personal computer. This data can be stored indefinitely and used again. The pre-cut vinyl film is then easily applied to the skin of the aircraft. Removal of the Gerber markings also takes less time than the original painted markings.

Benefits from using the Gerber machine include the following:

• A significant reduction in aircraft downtime (typically one day).

• A 90 percent reduction in hazardous waste.

• A significant reduction in the use of hazardous materials.

• A yearly labor and materials savings of $35,000.

• A payback period of only eight months ($12,000 invested).

Aqueous Part Washers and Recyclers As part of a military construction project, a new facility has recently been completed for the power plant’s division. This department is responsible for jet engine maintenance and testing operations. Original plans called for inclusion of a large six-vat vapor degreaser system. If implemented at MCAS Beaufort, approximately 19,000 pounds of hazardous waste annually was expected to be generated due to the use of several different types of hazardous solvents called for. Taking advantage of recent Naval approval authorizing the use of aqueous part washers for jet engine cleaning, the Air Station changed the original plans. Instead, three large industrial aqueous part washers, purchased by the environmental department, were procured and installed. This process will use a much less hazardous approved aqueous cleaner. In addition, augmenting the benefits of the part washers, two new wastewater treatment recycle systems were acquired that will periodically filter and clean the aqueous solutions of each washer. This process effectively recovers 80-90 percent of the solution, allowing for its indefinite reuse. On the whole, the new process described above, as opposed to the original design, is an effective, much less hazardous alternative that will minimize pollution.

Spent Fixer/Developer Recycling Each year approximately 2,500 pounds of spent fixer/developer chemicals from medical clinic and photo lab operations require disposal. The concentration of silver present requires disposal as a hazardous waste. Addition of silver-recovery systems at each location has reduced this waste stream by 80 percent. Now only the recycled cores (500 pounds per year) are manifested as a hazardous waste (for transport purposes only as required by law).

TECHNOLOGICAL SIGNIFICANCE

Of those projects described, the two having the most technological significance are the Gerber plotter and power plant’s aqueous wastewater recycling units. The Gerber plotter features state-of-the-art graphics software. The plotter and cutter assembly accommodate self-adhesive vinyl rolls up to 32 inches wide, permitting an assortment of fonts and sizes. Once the plotter has been programmed, jobs are saved as any other graphics file, instantly accessible for later use. Initiated at the touch of a button, the vinyl-cutting process is entirely automated. The use of paint for most stenciling operations is eliminated. This technique is now being evaluated for possible use throughout the Navy and Marine Corps.

The EQ-1 processors are the two wastewater treatment recycling systems. Made by the Mart Corporation, these units feature a unique process relatively new to the market place. Designed to be portable, they can be located and relocated as needed. Each unit is designed to process 225 gallons of dirty aqueous part-washer solution over a four-hour period. Duri The EQ-1 processors are the two wastewater treatment recycling ™ystems. Made by the Mart Corporation, these units feature a unique process relatively ne™ to the market place. Designed to be portable, the’ can be located and relocated as needed. Each unit ility, while targeting those particulates and contaminants inherent to the waste solution. The result is encapsulation of 80 to 90 percent of the contaminants in a sludge-like by-product. This by-product is allowed to dry, forming a material similar to cement, which is then ready for disposal. The process permits reclaiming and reuse of the wash solution and detergent indefinitely. As can best be determined, the Air Station is the first Marine Corps facility to use either the Gerber plotter or EQ-1 processor systems.

ECONOMIC BENEFITS

The economical benefits of MCAS Beaufort’s comprehensive pollution prevention efforts vary relative to specific projects. The Air Station’s CHRIMP program has realized total savings to date in excess of $302,000 and counting. Total investment for hardware, materials, and training was approximately $25,000. The Gerber machine project has already reached its payback period. As discussed earlier, realistic annual savings of $35,000 are expected. Operational costs for the remaining projects compared to the processes they replaced are almost equivalent. It is in the environmental benefits where profits are obtained. However, although not yet quantified, the long-term waste disposal cost savings from power plant’s use of the EQ-1 processors should prove substantial.

ENVIRONMENTAL SIGNIFICANCE

As a result of the comprehensive pollution prevention efforts described above, the Air Station has reduced the amount of hazardous waste generated annually by more than 50 percent; this downward trend continues. Nonexistent before 1996, reutilization of hazardous materials is now the norm versus the exception. Replacement of hazardous materials with less hazardous alternatives in part cleaning, aircraft demodexing, and jet engine cleaning operations have made for a safer workplace and lessened potential environmental impact.

COMMITMENT AND LEADERSHIP

As is true with all military organizations, the chain of command is very structured and rigidly followed. Additionally, in keeping with their primary defense directive, there is zero tolerance for anything having an adverse impact on overall mission success. Without command-level support from beginning to end, the projects described above could not have been implemented, nor would they continue. Indeed, MCAS Beaufort’s CHRIMP program was initially pursued at the behest of the Air Station and Marine Aircraft Group 31 commanding officers.

In his environmental protection policy statement, Commanding Officer MCAS Beaufort clearly states the level of commitment: "Our environmental program is based around pollution prevention, conservation, and compliance. Through education, awareness, and management, we will reduce or eliminate the amount of waste we produce. Reduction and waste prevention are not only environmentally sound, but the key to Fightertown’s fiscal survival. Each Marine and every civilian shares a responsibility for setting the example in environmental stewardship. We will lead by example, because with the environment, there are no second chances."

Dayco Products Inc.

Walterboro, SC

Winner -- Medium Sized Business or Industrial Facility

DESCRIPTION OF THE PROJECTS

Dayco Products, Inc., located in Walterboro, South Carolina, is a leading manufacturer of automotive and industrial V-belts. More than two million of these belts are produced every month, and they are distributed worldwide. In operation since 1973, Dayco–Walterboro celebrated its twenty-fifth anniversary in June 1998. The facility, which employs 305 people, has worked hard to reduce volatile organic compound (VOC) emissions, and it has aggressively pursued a recycling program.

TECHNOLOGICAL SIGNIFICANCE

Chemical substitution The replacement of solvent-based mold coatings and releases with new technology water-based silicones have dramatically reduced VOC emissions in the manufacturing process. These products are nonhazardous, nontoxic, and environmentally friendly.

The water-based materials currently being used are not ordinary "off-the-shelf" products; instead, they were developed specifically for the facility’s manufacturing process, which aims to use new advances in chemical coating and release technologies.

Recycling Through ISO 14001, Dayco-Walterboro encourages proactive procurement activities that focus on environmentally preferable products and services. In addition, the plant’s recycling activities help conserve natural resources and assist in "closing the loop." Other recycling activities include:

• Signing a major contract with Environmental Processing Systems, Inc., to recycle all of the facility’s scrap rubber; this program will commence in September 1999.

• Installing a dry dust-bagging system so that rubber dust can be recycled instead of being landfilled.

• Conducting engineering feasibility reviews to determine how Dayco-Walterboro can effectively recycle its contact cooling water and, consequently, eliminate its existing wastewater facility.

• Participating in Santee Cooper’s waste-oil recovery program, GOFER.

• Recycling fluorescent tubes off site.

• Sending hazardous waste off site for fuel blending.

ECONOMIC BENEFITS

The cost of the water-based materials is approximately the same as that of previously used solvents. It should be noted, however, that the product quality has improved and the health and safety benefits have turned out to be immeasurable. Environmental risks have also been greatly reduced. Furthermore, supporting new environmental technologies obviously has a favorable impact on the chemical industry and its end users.

The compensation received from the sale of rubber dust has, in one year, paid for the capital investment in the equipment. The recycling activities in the plant save tens of thousands of dollars annually through either the reuse of materials or the offsetting of costs through "landfill avoidance."

ENVIRONMENTAL SIGNIFICANCE

Chemical Substitution Source elimination is the facility’s primary strategy. The objective, simply stated, is as follows: Dayco-Walterboro will work toward "eliminating" all hazardous materials and, consequently, the associated emissions, wastes, and risks. In 1997, VOC emissions were reduced by 70 percent or 71 tons, in comparison to 1996 (Note: The production decrease for 1997 was 3 percent).

This plant assists other Dayco facilities by serving as a "test bed" for experimenting with new water-based coating and releases. Due to these partnering efforts, several other facilities are achieving major reductions in VOC emissions.

Water-based material substitutions also resulted in eliminating an entire hazardous material waste stream. In 1997, a reduction of 35 percent in total hazardous waste was achieved.

The environmental benefits of this project are far-reaching. Reductions in VOCs and hazardous materials result in cleaner air and reduced volumes of hazardous wastes. Wanting to make even further improvements, Dayco-Walterboro is now working with the same chemical companies to develop a water-based adhesive to replace its current solvent-based adhesives. If successful, the plant will nearly eliminate its remaining VOCs.

Recycling More than 1,700 gallons of used oil were recycled in 1997. That same year, the dust-bagging system helped recycle more than 70 tons of rubber dust. The facility has recycled 1,500 pounds of fluorescent tubes, and sent seven tons of hazardous waste off site for fuel blending. Signing a contract with Environmental Processing Systems, Inc., will result in about 1,800 tons of scrap rubber being recycled every year.

Also in 1997, Dayco-Walterboro recycled 120 tons of cardboard, 11 tons of paper, 67 tons of steel, and 90 tons of rubber.

COMMITMENT AND LEADERSHIP

Dayco-Walterboro’s commitment to pollution prevention and the environment is evident through its recent attainment of ISO 14001 registration. The company sees P2 as a win-win strategy, and ISO 14001 provides us with a mechanism for continuous improvement through pollution prevention.

The process of obtaining ISO 14001 registration from start to finish was completed in only five and a half months. A special feature of our management system is the integration of ISO 14001, QS9000, and our health and safety program into one system. Dayco-Walterboro is the first automotive supplier in the world to have this integrated system.

The results of our P2 efforts and recycling programs are a true measure of our commitment to pollution prevention. The adoption of ISO 14001 has elevated our existing P2 programs to an international level of excellence and environmental leadership. But our commitment and leadership can also be seen in other areas:

Information Sharing

• We have an active P2 committee.

• We have been featured in P2SC magazine and the SCDHEC Options newsletter.

• Dayco-Walterboro is a member of the Carolinas Air Pollution Control Association, Water Pollution Control Association, and the South Carolina Association for EHS Management.

• We conducted a presentation on ISO 14001 at a South Carolina Department of Defense Environmental Workshop at the request of Ms. Ann Clark, EQC, SCDHEC.

• Our facility has applied for the South Carolina Environmental Excellence Program.

• We participate on a regular basis in P2 information exchange with the Natural Resources and Environmental Affairs Office at the Marine Corps Air Station, Beaufort, SC.

Community Outreach

• We have provided volunteers to help install a playground and nature trail at a local elementary school.

• We have sponsored an Earth Day poster contest for children, and we conduct Earth Day presentations at local schools.

• We participate in the Adopt-a-Highway program.

• We participate in Leadership Colleton programs; a core curriculum includes protection of the environment.

• We provide members for the Colleton County Solid Waste Advisory Committee. This committee was chartered to make formal recommendations dealing with the construction of countywide solid waste collection and recycling centers. Due to the committee’s leadership, there are nine new centers in place today.

Communication and Awareness

• We openly communicate our environmental policy with the public. All employees carry a wallet-sized card that contains our environmental policy.

• We instituted our own "Clean P" logo, which represents Clean Process, Clean Product, Clean Plant, Clean Planet, etc. This logo is used extensively throughout the plant to promote environmental awareness. Employees can easily identify with its environmental and safety message.

• Our employees take pride in meeting their environmental responsibilities. We encourage employees to practice P2, both on and off the job.

Crown Cork & Seal

Spartanburg, SC

Honorable Mention -- Medium Sized Business or Industrial Facility

DESCRIPTION OF THE PROJECTS

Crown Cork & Seal Company’s business is the manufacture and sale of metal and plastic containers, crowns, aluminum and plastic closures, and the building of filling, packaging and handling machinery. These products are manufactured in eighty-nine plants in North America, and in more than one hundred forty plants outside North America; they are sold through the company’s own sales organization to the food, citrus, brewing, soft drink, oil, paint, toiletry, drug, antifreeze, chemical, and pet food industries.

The Spartanburg, South Carolina, facility is a producer of aerosol cans. In this process, tinplated steel is coated and decorated using a variety of coatings, inks, and solvents, which are—or contain—volatile organic compounds (VOCs). Source reduction and waste minimization are the focus of our pollution prevention efforts. Five projects have had a significant impact on pollution prevention at the Spartanburg facility.

Installation of a Regenerative Incinerator In October 1994, the company completed the installation of a regenerative incinerator at the Spartanburg facility. The total investment for this project exceeded $2.1 million.

Installation of the EPIC Dampening System In July 1994, the company completed the installation of the EPIC dampening system on Spartanburg’s three lithographic printing presses, which include two units on each press line. The total investment for this project exceeded $240,000.

Installation of an Ultraviolet (UV) Curing System In January 1997, the company completed the installation of a UV curing system, replacing a natural-gas-fired oven. The total investment for this project was about $260,000.

Installation of the Anilox Coating Application System In December 1996, the company completed the installation of the Anilox coating application system. The total investment for this project was about $100,000.

Increase in the Recycling of Solid Waste In October 1995, the company entered into an arrangement with Waste Management of South Carolina to increase the amount of paper and plastic recycled, and to reduce the amount of solid waste landfilled.

TECHNOLOGICAL SIGNIFICANCE

Regenerative Incinerator This type of incinerator provides a significant reduction in natural-gas consumption (approximately 80 percent over the previous system). Capture and destruction efficiencies are also greatly improved over the previous system. VOCs running through the system provide the bulk of the heat through their own combustion.

EPIC Dampening System This system provides efficiencies in setup time, improves print quality, reduces ink consumption, and eliminates the need for washing cloth-covered rubber rolls. The reduction in ink consumption helps reduce the volume of VOCs generated by the Spartanburg facility. The elimination of washing cloth covers also eliminated the main source of biochemical oxygen demand (BOD) contaminants discharged by the facility into the sanitary sewer.

UV Curing System This system eliminated the need for a natural gas-fired oven, reducing our natural gas consumption by approximately 13 percent annually. Along with the elimination of emissions from the burning of natural gas, VOC emissions have been eliminated on this lithography press line.

Anilox Coating Application System This system has provided increased control of the uniform filmweight application of coatings on sheets of tinplate. This increased control has allowed the facility to lower average filmweights for all coatings, thus reducing VOC emissions by approximately 7.50 percent.

Recycling Solid Waste The amount of paper and plastic collected for recycling by this facility has increased greatly—almost 75 percent in 1996 over 1995.

ECONOMIC BENEFITS

Regenerative Incinerator The Spartanburg facility has realized a $250,000 reduction in natural gas consumption. Airflow through the ovens has also improved, providing greater run efficiencies in the coating process. There has been approximately an 18 percent increase in productivity, partly due to the greater efficiency of the ovens.

EPIC Dampening System Ink consumption has been reduced by approximately 25 percent due to the installation of this new dampening system. Also, setup time has been reduced, and print quality has improved. There has been approximately a 10 percent increase in productivity in the lithographic presses.

UV Curing System The Spartanburg facility will realize a $15,000 savings in natural-gas consumption due to the installation of this system.

Anilox Coating Application System This system is expected to produce annual cost savings from reduced coating usage in excess of $140,000. The improved quality of the coating application is such that setup time on subsequent operations is reduced.

Recycling Solid Waste The Spartanburg facility received an additional $1,500 for recycled material in 1996 over 1995. Landfill costs were also reduced as a result of the plant’s work with waste management.

ENVIRONMENTAL SIGNIFICANCE

Regenerative Incinerator Capture efficiency has improved from 60 percent to 85 percent, and destructive efficiency has improved from 90 percent to 97 percent. Total emissions have been greatly reduced. The internal atmosphere of the facility has been greatly improved due to the increase in capture efficiency, thus improving the well-being and working conditions of the employees.

EPIC Dampening System The Spartanburg Sanitary Sewer District (represented by John Holcombe) toured the Spartanburg facility of Crown Cork & Seal after the installation of the EPIC Dampening System to determine the impact on the sewer discharge. After his tour, Mr. Holcombe approved the facility for semiannual monitoring versus quarterly monitoring as had been done in the past. There has been a reduction in BOD discharge since the installation of the EPIC system.

UV Curing System VOC emissions have been reduced, and emissions from burning natural gas have also been reduced by approximately 13 percent.

Anilox Coating Application System VOC emissions are expected to be reduced by approximately 7.50 percent due to the decreased average coating filmweights.

Recycling Solid Waste The amount of solid waste going to the landfill has been reduced by approximately 56 tons annually.

COMMITMENT AND LEADERSHIP

The top management commitment in our corporation has demonstrated that, more than ever before, leadership in the world community demands that we strive to minimize the environmental impact of all our business activities. This is best demonstrated in our Environmental Protection Policy, signed by our President, CEO, and Chairman of the Board, Mr. William J. Avery: "Crown Cork & Seal is committed to protection of health and environment in all areas where it conducts operations. Implementation of this policy is a primary management objective, and the responsibility of every Crown employee."

Our Corporate Director of Environment, Health and Safety, Mr. Robert G. Vatistas, has repeated this commitment to pollution prevention: "We at Crown Cork & Seal believe that incentives and volunteerism will be a successful way to manage the environmental issues this nation faces. Pollution prevention has enormous potential; source reduction is the wave of the future. Working together through proper management, organization and high-level commitment, we can achieve a common goal of public health protection and a clean environment to make our world a better place to live."