Universal Fasteners + P2 = $avings KPPC
to Co-Host National P2 Roundtable Conference The Smell
of Money Certified
Harardous Materials Manager Course P2/Green
Manufacturing ConferencetheBottomLine
Universal Fasteners + P2 = $avings KPPC
to Co-Host National P2 Roundtable Conference The Smell
of Money Certified
Harardous Materials Manager Course P2/Green
Manufacturing ConferenceYou see their products everyday: buttons, snaps, rivets, and burrs on those famous Levi Strauss and Lee jeans, as well as other apparel. What you don't see much of these days is their waste. Universal Fasteners Inc. (UFI) of Lawrenceburg, Kentucky, is a textbook example of how pollution prevention helps a major manufacturer save money and landfill space.
Years ago, UFI began recycling office paper, computer paper, and aluminum cans.
Over the years, UFI has profited by increasing its wastestream recycling, according to Todd Baldwin, UFI environmental engineer. Several types of scrap metal generated by the processes in the facility returns an average of $1.5 million annually. However, Baldwin does not see this figure increasing, since UFI is at or near production capacity.
The Pallet Problem
Like so many manufacturers, UFI receives more pallets than they can use. Some are reused, but the majority are unsuitable for shipping finished UFI products. Pallet recyclers abound, but shipping costs can make pallet recycling prohibitive. This was UFI's problem, and most of their pallets wound up in the local landfill.
In 1994, a high school senior from Frankfort approached Todd about taking the pallets. Today his company reconditions and resells some of UFI's pallets, and grinds the rest for mulch. Weekly pickups minimize storage problems.
Wetscrubbers
According to Baldwin, the processes used at UFI are identical to that of an automobile manufacturer, only on a much smaller scale. The Lawrenceburg facility has four electroplating lines: copper, nickel, zinc, and decorative (brass, tin, antique and black nickel). Each line has a dedicated venturri scrubber or wetscrubber, each with about 95% recovery efficiency.
Each line also contains a number of drag-out tanks, meaning more metal stays in the plating process and less metal has to be treated on-site through the wastewater treatment system. To recover nickel from the process, the nickel plating line utilizes a reverse osmosis unit. A copper recovery unit is employed on the copper plating line to recover copper which has a purity rate greater than 99 percent. The recovered copper can be reused in the copper anode plating bath.
No More Sludge Drudge
Previously, the burnishing sludge - a non-hazardous special waste - was combined with sludge from the electroplating process. Because electroplating sludge is a listed hazardous waste, this made all the sludge hazardous. The facility shipped a 20 cubic yard roll-off off-site about every two weeks. The material was wet and at about the cost of $3,800 per load, sludge disposal cost kept increasing.
In 1992, UFI purchased and installed a sludge dryer. By removing water from the generated sludge, the results were an impressive $55,000 annual savings at the Lawrenceburg facility alone.
Even though sludge drying was cost effective, the amount of hazardous waste generated by the facility was still the same. Baldwin and his colleagues estimated that 80 percent of the mixed sludge was non-hazardous and decided to separate the wastestreams in 1995. They discovered that 90 percent or more of the separated sludge is non-hazardous. This saved UFI an additional $45,000 annually in disposal costs. The total savings from drying and separating the sludge waste was approximately $100,000 per year.
Due to the cost of hazardous waste disposal, the sludge dryer is currently used in the plating sludge process, and the burnishing sludge remains wet. As an added step in 1997, UFI was able to successfully recycle the plating sludge through ENCYCLE/TEXAS, INC. UFI's plating sludge contains 14-16 percent copper. The sludge is mixed with comparable wastestreams and sold to a copper smelter. The material leftover from this process is a fly-ash material which enables UFI to reduce its liability by eliminating the disposal of the sludge to a hazardous waste landfill.
Paint, Lacquer Waste
UFI employs a 30-gallon still for on-site recovery of used solvent. This recovered solvent is used to clean out the paint guns. Paint and lacquer waste decreased from 12 drums per month to six drums, with an annual cost savings of about $30,000. Leftover still bottoms from the paint waste and the added lacquer waste is recycled by blending it as a primary fuel for a cement kiln. Paint and lacquer waste, with its high BTU value, is a prized fuel for kilns.
Old Friends
UFI and the Kentucky Pollution Prevention Center have had
a long relationship over the years. Baldwin says that assessments by KPPC revealed P2
opportunities they had already discussed, but proved valuable in convincing management to
go along. "We were able to say, look, here's this outside group that has no ulterior
motive, and these are their recommendations." Baldwin said. As a result of their
success with P2 practices, UFI continues looking for ways to cut waste and boost their
bottom line. 
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The Kentucky Pollution Prevention Center will co-host the National Pollution Prevention Roundtable’s (NPPR) Annual Spring 1998 Conference in Cincinnati, Ohio from April 28 to May 1. The conference will highlight the latest in pollution prevention (P2) policy, and regulatory, technical, and industrial assistance initiatives. Plenary sessions will feature lawmakers and government officials discussing the next steps for P2 to become a centerpiece of federal government environmental policy, as well as at the state and local levels. Reauthorizing the Pollution Prevention Act of 1990 to strengthen the national commitment to P2 will be discussed. Chemical Use Reporting and P2 Planning will also be discussed. A special update on the Roundtable’s Materials Accounting Project and pilot program is scheduled.
Session Topics
Several new cutting edge sessions from the 1997 Spring Conference will be expanded. These sessions will explore ways that P2 can be highlighted more on the Internet and through current and future international partners. A new, special track will focus on global climate change as energy efficiency topics. The popular sustainable development, household/landscaping P2, and technical paper sessions will be expanded. Other innovative programs will be showcased in numerous other topical sessions including Local Government, Small Business, Regulatory Integration and Education, Training and Learning.
The 1998 Spring Conference is expected to have about 700 participants. Attendees will be from:
 | federal, state, and local government agencies |
| trade associations |
| academic institutions |
| private industry |
| nonprofit organizations |
This diverse group of P2 experts makes the NPPR Spring Conference the largest P2 conference of its kind in the country.
Fees and Early Registration
Conference fees include registration and all accompanied materials, three continental breakfasts, two lunches, and three receptions.
NPPR is the largest membership association devoted solely
to promoting P2. For more information, contact the NPPR office at (202) 466-3908 or
through e-mail at micherusso@ compuserve.com.
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It started out more like a nightmare than a dream come true. In 1979, Jim Nichols first smelled the problem in his backyard before he actually saw it - his septic system had backed up. Rather than view this as a problem, Jim saw the opportunity to build a better mouse trap, or in this case, a better septic system. Thus began Infiltrator Systems, Inc. (Infiltrator Systems).
In just 18 years, Jim Nichols and his partner George Haines have turned an idea into a reality. Infiltrator Systems has grown from the original office in Old Saybrook, Connecticut, where manufacturing was outsourced to contractors, to include two manufacturing facilities in Winchester, Kentucky (1991) and Ogden, Utah (1995).
Infiltrator Systems has also entered the stormwater management arena with the development of a similar type system designed to replace ponds, large diameter pipe and stone discharge lines, vaults, and dry wells.
The road to success, however, has not always been easy. Their new product required state regulatory approval. In addition, they had to find investors for the company. But hard work and determination paid off, and by December 1, 1986 Infiltrator Systems, Inc. became a reality.
How Does It Work?
So just what is this new septic system and how does it work? The infiltrator system replaces conventional stone and pipe lateral systems typically associated with most septic leach fields. The system is a plastic arched chamber with louvered sidewalls. These sidewalls are designed to allow effluent to pass laterally into the soil while preventing backfill intrusion of the surrounding soil into the chamber. The chamber bottom is completely open, which further promotes effluent infiltration into the underlying soil.
The infiltrator system is molded of a proprietary blend of high-density PolyTuffTM polyethylene which includes recycled resins. Because of this unique composition, the system can use up to 90 percent recycled plastic material.
Champion Emerges
As the demand for the infiltrator system has grown (over 5 million chambers have been installed in 46 states, Canada, and other countries) so too has the demand for plastic. Infiltrator Systems processes more than 250,000 pounds of plastic daily to support production demands from their two manufacturing facilities. To meet this demand, Champion Polymer Recycling (a Division of Infiltrator Systems) was established in 1995 in Winchester, Kentucky.
Send Your Plastic and Co-Polymer Polypropylene
Champion purchases ground and unground parts, chunks/lumps, and purgings of low density polyethylene (LDPE), medium density polyethylene (MDPE), and high density polyethylene (HDPE), of medium-to-high melt injection grade in mixed colors. This material can include anything from buckets, tubs, lids, and crates to numerous other types of material.
To keep up with the demand of the infiltrator system,
Champion requires more than 100 tons of recycled plastic daily. What this essentially
boils down to is that Champion will take any and every piece of plastic that meets their
specifications. With manufacturing locations in the eastern and western United States,
Champion will accept material sourced from just about any location within the continental
U.S. Give them a call and put your scrap plastic to good use. To see if your material is
suitable, call Champion Polymer representative Chuck Harms at (606) 744-5858 or Don Douglass of the Kentucky Pollution Prevention
Center at (502) 852-1560.
- Don Douglass
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What’s a CHMM?
CHMM stands for Certified Hazardous Materials Manager. The CHMM is a professional credential granted to professionals engaged in the management and engineering control of hazardous materials who have attained the required level of education, experience, and competence.
What Does a CHMM Do?
A CHMM serves as a catalyst by identifying hazards which contribute to problems and implementing sound procedures to reduce the risk. Professional hazardous material management is a broad approach using engineering, environmental science, industrial hygiene, behavioral science, economics, management science and other related disciplines. In other words, a CHMM incorporates sound knowledge of regulations, material characteristics, production requirements, logistics, and general management to do the job effectively.
Where do CHMMs Work?
They work in most types of manufacturing facilities, waste treatment facilities, government agencies, the military, consulting groups, law firms, and transportation companies. A CHMM is regarded as the “expert” in managing hazardous materials safely.
How do You Become a CHMM?
You may request an application packet from the Institute of Hazardous Materials Managers by calling (301) 984-8969. If your experience and academic credentials are sufficient, the Institute will certify you to sit for the credentialing exam. This is a rigorous test given at proctored sites across the country. The Institute can provide you with a test schedule.
How do You Prepare for the Exam?
Many candidates take a review course to prepare for the CHMM exam. In Louisville, the course is sponsored by the Kentuckiana Chapter of Hazardous Materials Managers (KCHMM) and the University of Louisville. The next course will be held October 14-16 on U of L’s Shelby Campus. For information, call Judy Hasselback at (502) 852-5658. The course is also a way to improve your knowledge of EPA, DOT, and OSHA regulations affecting the management of hazardous materials. The cost is $495 ($375 for government employees) for three days of expert instruction.
How Do I Contact the Local Chapter?
In Louisville, call Denise Jerome at (502) 241-4130. Their next meeting is November 5, and you don’t have to be a CHMM to join.
If you’re outside the Louisville area, find your
local CHMM chapter by calling the Academy of Hazardous Management toll free at (800)
437-0137.
- Evelyn Crooks
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The Environmental Protection Agency, Region 4, is sponsoring a Pollution Prevention/Green Manufacturing Conference for Industry and Business in the Southeast. The conference will be held on November 17-19, 1997 at the Marriott Marquis Hotel in Downtown Atlanta.
The conference will include presentations by industry leaders on how to reduce and even eliminate hazardous waste generation, solid waste, wastewater discharges, and air emissions. The benefits from such reductions include costs savings in waste treatment and disposal, compliance with regulatory requirements, and, in some cases, exclusion from a regulated status. Sources of free technical assistance and information will be presented.
The conference will also include presentations on ISO 14000 and Environmental Management Systems (EMS), explaining why every manufacturing facility needs an EMS even if they have no desire for certification under ISO 14000.
For conference information, call (404) 562-9362.
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theBottomLine is a quarterly pollution prevention newsletter published by the Kentucky Pollution Prevention Center at the University of Louisville.
Editor: Patricia Longfellow
Executive Director: Cam Metcalf
Contributing staff: Donald Douglass, Mary Joyce Freibert,
Arnita Gadson, Allan Handmaker, Melinda Latham, Keith Ridley, Mary Watson, Penny Williams
For more information write to:
Kentucky Pollution
Prevention Center
University of Louisville
Louisville, Kentucky 40292
phone: (502) 852-0965
or (800) 334-8635 ext. 0965