Waste Reduction for the Commercial Printing Industry
Introduction
The commercial printing industry generates hazardous waste as a result of its variety of operations. This fact sheet introduces the hazardous waste reduction concept specifically for the commercial printing industry. Printers may incorporate this concept and the fact sheet's suggestions into their overall operations and save money on hazardous waste management costs while protecting their workers and the environment.
Wastestreams Typical of the Commercial Printing Industry:
- Waste photochemical solutions and films (For example, some negative developers for lithography are classified as hazardous as products and may also be hazardous as wastes under state regulations).
- Waste inks containing hazardous components (often metallic pigments and solvents).
- Ink-contaminated solvents and rags used for cleaning.
- Lubricating oils from machinery.
- Spent solvents such as Carbon Tetrachloride, Perchloromethane, Ethanol, Isopropanol, I,I,I-Trichloroethane, and Methylene Chloride.
- Strong acid/alkaline etch and counter-etch solutions.
Waste Reduction Incentives
Hazardous waste reduction can be an effective, economic way to reduce hazardous waste management costs. In some instances, it may require some initial capital investment to introduce and implement waste reduction practices. However, these "up-front costs" could be quickly recovered when hazardous waste management and liability costs are reduced. Other advantages include:
- Reduced tax burden from generator fees, land disposal fees and taxes.
- A safer workplace for employees.
- Reduced compliance requirements.
New Jersey Department of Environmental Protection
Division of Hazardous Waste Management
Hazardous Waste Advisement Program
Bureau of Regulation and Classification
- Reduced threat to the environment.
- Improved corporate image in the community.
Waste Reduction Requirements
The New Jersey state regulations (N.J.A.C. 7:26-7.4(g)) require that generators of hazardous waste file an Annual Generator's Report. Among other requirements, this report must include a description of the efforts undertaken, during the reporting period, to reduce the volume and toxicity of wastes generated. For more information on the annual report call (609) 292-7081.
The Uniform Hazardous Waste Manifest requires that large quantity generators (those generating greater than 220 pounds or 100 kilograms of hazardous waste) certify that they "have a program in place to reduce the volume and toxicity of waste generated" and that they have selected the "most practicable method of treatment, storage, or disposal currently available... which minimizes the present and future threat to human health and the environment."
Waste Reduction Alternatives
Management Commitment
An important aspect of any waste reduction program is management commitment. The commitment shows employees that managers place a high priority on waste reduction. For example, a conspicuously posted shop policy, signed by top management, requiring waste reduction will aid in making it a critical part of all day-to-day activities. All employees must be encouraged to participate in reducing wastes to the greatest extent possible.
In addition, if an employee is placed in charge of identifying ways to reduce wastes, he or she must be given the cooperation, by both employees and management, necessary to implement changes in shop operations.
Employee Awareness
- Hazardous waste reduction efforts should be emphasized to each employee, from the general manager to machinery operators.
- Employee suggestions should be encouraged through a merit program or some other type of incentive.
Good Housekeeping
- Segregate wastes to increase recyclability.
- Keep careful records of inventory control. Implement a 'first-in, first out' policy of chemical product use. Do not order more than 'can be used within the shelf life' of the product. Label contents and expiration dates should be legible.
- Designate one person, usually the shipping and receiving clerk, to manage raw materials for proper inventory control and to ensure that hazardous substances are properly contained and labeled, and that a Material Safety Data Sheet (MSDS) is on file.
- If materials have exceeded their shelf life, check on alternative use before discarding. Consider contacting nearby theater groups or college graphic arts departments to donate expired materials for their programs. Also, buy only from a manufacturer that will accept materials back if shelf life is exceeded.
- Minimize spills and use dry methods for cleanup wherever possible. If a spill of a hazardous substance occurs, use an absorptive material to soak it up and dispose of spill cleanup residue in accordance with all local, state and federal regulations.
- Monitor printing press performance continuously to minimize bad runs and waste. There are commercially available detectors and other equipment for this purpose.
- In larger businesses, make sure hazardous waste generating departments are billed for management, compliance and disposal costs incurred by their activities. Hazardous waste management costs covered under a general expense fund do not give specific departments an incentive to reduce their wastes.
- Be innovative in trying new procedures and products.
- Find ways to use "scrap" paper. Make notepads, poster-paper or other products from extra paper. Recycle all paper waste or donate it to schools and churches. Recycle aluminum plates, negatives and any other silver laden paper.
Image Processing
Silver compounds are classified as hazardous wastes under state and federal law if liquid wastes exceed five milligrams per liter of silver at a pH of 5.0. If process baths are discharged into the sewer, a permit by the local sanitation department is usually required. Concentrations of silver-contaminated wastewater must be maintained below the limits established by the sewer authorities.
Ways to Manage Silver
- Eliminate it by using silver-free films. Some silverless products are vesicular, diazo and eletrostatic films. Photopolymer films contain carbon black as a substitute for silver.
- Recover silver from fixing baths and have a commercial recycler pick it up. Purchase a silver recovery unit and perform the recycling of fixer on premises.
- Add ammonium thiosulfate to silver contaminated baths to extend the allowable buildup of silver.
Process Baths
- Use an acid stop bath prior to the fixing bath. This reduces the effect of an alkaline developer on the fixing bath pH. Add acetic acid to the fixing bath, keeping the pH low to maximize soluble complexes.
- Use floating lids on bleach and developer containers to keep them fresh.
- Install waterless paper and film developing units to reduce the volume of fixer waste. Segregate fixer from developer wastes.
- Substitute non-hazardous raw materials for hazardous materials whenever possible.
- Install electronic imaging and/or laser platemaking. By editing on a video terminal, the need for photographing and reshooting can be reduced. This alternative is costly. Make sure the payback period is evaluated before purchase.
- Employ countercurrent rather than parallel rinse techniques. Countercurrent rinsing means water from previous rinsings is used in the initial film washing stage. Fresh water enter the process at the final rinse stage, at which point much of the contamination is already rinsed off the film.
- Protect process baths that spoil easily by keeping them containerized. Small scale photo developers can containerize process baths and use glass marbles to bring the liquid level to the brim each time the liquid is used.
- Using personal computers with commercial publishing capabilities allows the user to set up and edit jobs before going to print. Materials, time and waste are reduced from draft to final product.
Plate Processing
Replace metal etching processes, with the associated hazardous chemical solutions and heavy metals, wherever possible.
Alternative Plates Include:
- Presensitized lithographic - some solutions resulting from these plates can be discharged to the industrial sewer with written authorization or permit from the sanitation district. Water based solutions are currently available and widely used. The plates can be sold to an aluminum recycler.
- Plastic or photopolymer - generally these are processed with a water based solution containing little or no hazardous waste.
- Flexographic.
- Electrostatic - paper plates made directly from artwork are used on copier/duplicator presses and eliminate several process steps.
In addition, hot metal can be remelted or sold to a recycler.
Printing and Finishing
Inks
Many clients would use less hazardous products if given the choice, provided that product quality is not compromised. Inform clients of specific inks that are recyclable or are not hazardous and provide samples illustrating finished products. Encourage them to select these materials.
The composition of inks varies widely. Some inks contain chemicals that would be classified as hazardous; others do not. Inks frequently get their color from the metals or hazardous pigments they contain. Inks containing metals and/or those using a solvent carrier are often classified as hazardous. It is the responsibility of shop owners to determine whether the inks used in their operations are hazardous. For assistance in making the determination, review the container label, the MSDA, or ask your ink distributor (You can also contact the Department's Waste Classification Unit at 609-292-8341 for more information.)
Most inks can be recycled; they are often blended to make black ink. For smaller print shops, consider coordinating with larger plants or newspapers (that use a rubber or oil based ink) to recycle ink. These businesses usually recycle their inks on-site or ship them off-site in bulk shipments. Also consider purchasing inks from a distributor who will take or buy back unused or spent inks.
Waste Reduction Alternatives for Inks
- Fill ink fountains only enough for a particular run or shift. Return all unemulsified inks to their containers. Install automatic ink levelers to keep ink fountains at their optimal level for good print quality in large web presses.
- Run similar jobs simultaneously to reduce waste generation between cleanup and start of the next run.
- Use water based inks whenever possible to cut down on the use of solvent based inks that cause employee and environmental hazards.
- Clean ink fountains only when changing colors or when the ink might dry out between runs to reduce waste ink generation. Fountains can be left with ink overnight if sprayed with special non-drying aerosol materials.
- Dedicate one press for inks with hazardous pigments or solvents.
- Save old inks and market as "house colors".
- Donate unemulsified inks to trade schools, colleges, etc.
Advantages of Water-Based Inks (flexographic and gravure processes)
- Water-based inks are often classified as non-hazardous.
- No special air pollution control equipment is required for emissions.
- Less toxic to employees.
- Reduced disposal cost.
Advantages of Ultraviolet Inks
- Quickly dry when exposed to ultraviolet light.
- Can remain in ink fountains for long periods without drying.
- Eliminate "set off" thus eliminating the need for anti-offset sprays.
- Eliminate ventilated storage of sheets during oxidative drying.
Advantages of Electron Beam Drying (EB) (used on web presses)
- Similar in use to ultraviolet inks.
- Uses less solvent than heat-set inks.
Isopropyl Alcohol
Use a fountain solution that contains low concentrations of isopropyl alcohol (IPA) or one containing no IPA. IPA emissions can cause air pollution problems and may require the installation of pollution control equipment. Substitutes are available. Operational adjustments may be required to make them work well, but the alternative cost of air pollution control equipment installation can make the effort economically worthwhile.
Waste Solvents
Waste solvents are generated when cleaning presses. These wastes are considered hazardous and should be recycled. For a listing of recycling companies, check the telephone book under "Solvents" or contact the Hazardous Waste Advisement Program for a list of commercial recyclers. Solvents may not be disposed of to land. Discharge of solvents to the industrial sewer is, in general, not allowed.
Rags become contaminated with ink and solvent. Contaminated rags to be disposed of are considered hazardous waste. The disposable rags must be stored separately from municipal trash and transported according to hazardous waste regulations.
Solvent Alternatives
- Use soap or detergent solutions wherever possible. Use solvents only for cleaning inks and oils.
- Specially made blanket washes that do not contain hazardous materials are now available. Check for emission control requirements of these washes with Air Pollution Control Unit at 1-800-441-0065. You should also check with the Department's Bureau of New Source Review at (609)-292-6716.
- Small solvent recovery systems are currently on the market and work well.
- Many acetic acid based solvents are on the market and are less toxic than other solvents.
Waste Lubricating Oils
Lubricating oils should be managed as hazardous wastes when they have no further use. Call the Hazardous Waste Advisement Program at (609) 292-8341 for information on waste oil handling. Waste oil must be transported by a hazardous waste hauler registered with the New Jersey Department of Environmental Protection.
Additional Publications
Disposal of Small Volumes of Photographic Processing Solutions
Eastman-Kodak Publication J-52
343 State Street, Rochester, N.Y., 14650
Waste Audit Study - Commercial Printing Industry
California Department of Health Services, Toxic Substances
Control Division, May 1988
Waste Minimization, Issues and Options
Volume II
United States Environmental Protection Agency
Office of Solid Waste and Emergency Response
October 1986
Environmental Aspects of Chemical Use in Printing Operations Conference Proceedings
United States Environmental Protection Agency
Office of Toxic Substances
January 1976
The following additional publications which may be helpful in overall management of hazardous waste are available from the Hazardous Waste Advisement Program.
Hazardous Waste Information Series:
- Classification of Hazardous Waste
- Generators
- Hazardous Waste Minimization
- New Jersey's Hazardous Waste Regulatory Program
- Standards for Hazardous Waste Treatment, Storage and Disposal Facilities
- Toxics in the Home
- Transporters
- Uniform Hazardous Waste Manifest
News Letters:
- Hazardous Waste Quarterly
- Small Quantity Generator Newsletter (9/88)
Technical Information Publications (TIP):
- Metal Manufacturing
- Vehicle Maintenance
Waste Minimization Publications:
- 8/85 Waste Minimization Seminar Proceeding
- 11/87 Waste Minimization Workshop Proceedings
- 5/89 Waste Minimization Conference Proceedings
- Assessment of Reduction and Recycling Opportunities for Hazardous Waste Manual
- Pollution Prevention Grant Program Summary
Other Publications:
- A Citizen's Guide to the Major Hazardous Waste Facilities Siting Act
- List of Commercial Hazardous Waste Facilities in New Jersey
- New Jersey's Hazardous Waste Management Program
- Hazardous Waste Q&A
Regulations:
- Hazardous Waste Regulations (N.J.A.C. 7:26-1 et al.)
- Unified Hazardous Substance List
Water Resources Publications:
- Field Guide
- Resource Manual
- Clean Water Book
- Non-Point Source Pollution
- Solution to Pollution
Further Information
For information about regulatory requirements contact the Hazardous Waste Advisement Program at (609) 292-8341 or write to:
New Jersey Department of Environmental Protection
Division of Hazardous Waste Management
401 East Street, CN028, 5th Floor
Trenton, New Jersey 08625
Attn: Hazardous Waste Advisement Program
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Last Updated: January 4, 1996