Fact Sheet On The Hazardous Waste Generated By The Printing Industry

California Department of Health Services
Toxic Substances Control Program
Alternative Technology Division

April 1990

Waste Introduction Reduction

The commercial printing industry generates hazardous waste as a result of its operations. 'Me California Department of Health Services, Toxic Substances for the Control Program (TSCP) regulates the generation, treatment, storage, transport and disposal of hazardous wastes throughout the state. 'De TSCP is committed Commercial to reducing hazardous wastes generated to the greatest extent possible. As part of this effort, studies investigating alternative management strategies to reduce Printing hazardous waste have been completed. This fact sheet introduces the hazardous waste audit study conducted specifically for the commercial printing industry.

Industry

Many companies today have incorporated these options into their overall operations and are saving money on hazardous waste management costs while protecting their workers and the environment.

Waste streams 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

• Reduced tax burden from generator fees, land disposal fees and taxes
  
• A safer workplace for employees
  
• Reduced compliance requirements
  
• Reduced threat to the environment
  
• Improved corporate image in the community

Both state (Health and Safety Code, Article 11.8, Section 25244.4) and federal (Title 40 Code of Federal Regulations, Part 262, Subpart D) laws and regulations require that generators of hazardous waste file a biennial generator's report if more than 5 tons of waste per year are generated. Among other things, 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 biennial reports call (916) 322-3913.

Generators of recyclable wastes who are not currently recycling must also provide, if requested by the TSCP, a written statement to justify not recycling the waste (Title 22, Article 12, Section 66763 of the California Code of Regulations (CCR)).

The Uniform Hazardous Waste Manifest requires that large quantity generators (those generating greater than 2200 pounds of solid waste or 264 gallons of liquid 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." Small quantity generators (those who generate greater than 220 pounds (26 gallons) but less than 2200 pounds per month of federally designated hazardous waste) must certify that they have made a "good faith effort to minimize waste generation and have selected the best affordable waste management method available".

• What can you do to reduce hazardous wastes at your shop?

  A. Start with good operating practices.

Management Commitment

An important aspect of any waste reduction program is management commitment. 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.

Also, 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.

If materials have exceeded their shelf life, check on alternative uses 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 it in accordance with all local, state and federal regulations.

• Monitor 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 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 local limits established by each sewering agency.

Ways to Manage Silver

• Eliminate it by using silver-free films. Some silverless products are vesicular, diazo and electrostatic 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 waste.
  
• 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 rinsing is used in the initial film washing stage. Fresh water enters 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 photodevelopers 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:
  
  1. 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.
     
  2. Plastic or photopolymer - generally these are processed with an water based solution containing little or no hazardous waste.
     
  3. Flexographic
     
  4. 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.

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 MSDS, or ask your ink distributor (You can also contact the TSCP's Waste Evaluation Unit at (916) 324-1807 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 arc often classified as nonhazardous
  
• 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 TSCP's Alternative Technology Division at (916) 324-1807 for a free copy of the California Waste Exchange Directory. 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, nonsaturated rags are not considered hazardous wastes by the federal and state government if they are laundered and reused but contaminated rags to be disposed of are. 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. These washes also meet emission requirements of the various air pollution control districts in California.
  
• 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 California Waste Management Board's Waste Oil Hotline at 1-800-553-2962 for information on waste oil handling. For large quantities of oil, look in the Yellow Pages of the telephone book under "Oils-Waste" for a transporter registered with the State of California to haul hazardous wastes for recycling.

• 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.

Department of Health Services
Toxic Substances Control Program
Alternative Technology Division*
714/744 P Street
P.O. Box 942732
Sacramento, CA 94234-7320
(916) 324-1807*

To get an EPA ID number, call:*

DHS, Toxics Program
Program and Administrative Support Division
(916) 324-1781

9056699

State of California - Health and Welfare

Department of Health Services
Toxic Substances Control Program
714/744 P Street
P.O. Box 942732
Sacramento. CA 94234-7320

For information about your regulatory requirements, contact the DHS regional office nearest you:

Region I	Sacramento (916) 855-7700 Fresno (209) 445-5938
Region 2	Berkeley (415) 540-2122
Region 3	Burbank (818) 567-3000
Region 4	Long Beach (213) 590-4868

In addition, print shop owners and operators may be able to obtain information from:

• Registered hazardous waste haulers
  
• Printing Industries Association of Northern and Southern California
  
• Recycling treatment equipment vendors
  
• Informational workshops