Pollution Prevention Case Study

Nicolet Paper Company

Reduction of Xylene, flammable inks, and other wastes through substitution and reuse
Standard Industrial Classification (SIC) Paper Mills/2621
Type of Waste Xylene, Paper Waste, Flammable Inks
Strategy Material Substitution, Process Modification Management
Company Background Nicolet Paper Company manufactures glassine and backing papers used in such applications as: food packaging; envelope windows; and release liner for adhesive-backed labels. The facility has been in operation since 1892 and originally made high-grade writing papers from cotton cloth. In 1927, the company switched production from writing paper to glassine and greaseproof papers made from wood pulp. Glassine and greaseproof papers were used principally for packaging products such as candy bars, cereals, and potato chips. While glassine is still used today, many of its former uses have been replaced by plastics. International Paper acquired the mill in 1986. Since 1987, a high performance work system has been in place that encourages participation by employees at all levels. The facility employs approximately 370 people and operates 24 hours per day, 365 days per year.
Original Process Nicolet Paper established specific goals for the reduction of solid and hazardous waste generation and for the release of xylene from the facility.
Motivation These goals were based on International Paper's Environmental Principles which were established in 1992. The company sought to:
  • Reduce solid waste through beneficial reuse and recycling.
  • Reduce hazardous waste through product elimination and substitution, and development of a chemical procurement process.
  • Reduce xylene air emissions through equipment upgrades, written procedures, and chemical substitution.
  • Reduce particulate matter releases through installation of an electrostatic precipitator.
Pollution Prevention Process Xylene air emissions were reduced through: the installation of doctor blades to minimize pitch buildup on paper machines; the implementation of procedures which specify solvent usage; and partial substitution with isopropyl alcohol. A formal task team continues efforts to find a permanent replacement for xylene.

To date, solid waste reductions have resulted from concentrated efforts to recycle paper, cores, and metal and the beneficial reuse of a significant portion of Nicolet's paper mill sludge by an in-state paperboard manufacturer. From 1991 through 1994, generation of solid waste dropped by 34 percent, while paper production increased by 25 percent.

Hazardous waste was reduced significantly when a product line utilizing flammable inks was eliminated in 1993. Ongoing efforts include product substitution and a complex chemical application process that provides an organized, systematic approach to chemical purchasing. The process seeks to screen out chemicals which may be detrimental to the environment, health, and safety objectives. Nicolet achieved an important milestone in May of 1994, when it formally changed status to small quantity generator.
Material/Energy Balance  

WASTE REDUCTION
Category

1991

1992

1993

1994

1995*
Solid Waste

38.9

28.6

25.1

18.9

17.3
Haz Waste

35,569

5,119

11,528

1,416

1,441
Xylene

14,080

10,110

9,017

4,511

1,860
Particulates

984

264

260

122

122

Note: Solid waste in cubic yards/100 finished tons, Hazardous Waste and Xylene in pounds.
Particulates in pounds/day.
*1995 data through June.

RECYCLING/REUSE
Material

1993

1994

1995
Paper

110,780

210,710

218,029
Cores

68,370

174,948

109,417
Metal

153,880

403,296

163,260
Sludge

0

3,610,000

3,952,000
Economics

Please click on graphs for larger view

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Capital Costs

 graph
No capital costs were associated with these reductions.

Operational Costs
None.

Payback Period
Recycling activities have provided a good level of savings in landfill tipping fees and product value. Costs associated with hazardous waste disposal have decreased significantly over the last several years.

Disposal Costs

1992

1993

1994
Hazardous Waste Disposal
(Approximate Costs)

$21,524

$9,790

$900
Recycling Savings (Approximate)

1992

1993

1994
Paper, Cores, and Metal

No Data

$6,151

$21,864
Sludge

$0

$0

$13,865
Benefits Waste reduction activities have resulted in cost savings and in some cases have generated revenue.
Obstacles A main obstacle for the elimination of xylene continues to be identification of an effective substitute which is compatible with existing machinery. Beneficial reuse of sludge as a raw material required the identification of a consumer to use the material. Several options were investigated before the current arrangement was established.
Other Pollution Prevention Activities Nicolet Paper understands that education of employees is the key to a successful recycling program. Nicolet has ongoing efforts to improve recycling through newsletter articles, announcements, and instructional postings.
Technology Transfer Effective implementation of a program such as this can be achieved through management support, employee involvement and integration of all aspects of waste generation to identify and eliminate or reduce waste at its source.
Company Address Nicolet Paper Company
200 Main Avenue
De Pere, Wisconsin 54115
Contact Person Thomas Piette, EHS & Utilities Manager
414/337-1270
Pollution Prevention Resources Free, On-site Technical Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385

Industrial Waste Reduction Information Clearinghouse
Wisconsin Department of Natural Resources
Bureau of Cooperative Environmental Assistance
608/267-9700
DNR Logo


Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI   53707
608/267-9700

PUBL-TS-057 96