INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE

Case Study #272

1.   Headline:  Internal recycling in a flexographic printing
     facility reduces effluents

2.   Background:  Further to the adoption of flexographic
     printing, the Cartonnages de l'Agenais studied how to
     recycle the printers washing water to overcome pollution
     and effluents coloring. A technique using ultrafiltration
     was selected.  This case study was carried out in 1992.

3.   Cleaner Production Principle:  internal recycling

4.   Description of Cleaner Production Application:

     Information about the process and wastes

     The flexographic inks contain organic pigments without any
     heavy metals. The washing water (1.5 m3/day), containing 1
     % of ink can not be discharged outside due to its color, a
     rate of suspended matter over 200 mg/l, and a COD over 400
     mg/l.

     The company has installed ultrafiltration enabling it to
     reuse the purified water and to treat only a concentrated
     effluent.

     The process is based on ultrafiltration using mineral
     membranes operating in tangential flow. The turbulent
     brushing of the membrane surface prevents particles from
     accumulating and clogging, which renders useless the
     cleaning processes with chemical reagent.

     Both modules with mineral membranes CARBOSEP enable 6 to 8
     m3 a week to be treated. The high thermal, chemical and
     mechanical resistance of the mineral membranes offers
     almost total protection in case of accidental pollution.
     The facility is entirely automated.

     Level of marketing:  The TECH-SEP company has built an
     industrial prototype, the first facility able to treat
     water containing ink using ultrafiltration by means of a
     mineral membrane in tangential flow.

    Material / energy balance and substitution

     Drinking water saving : 400 m3/year.

5.   Economics:

    Cost of direct investment

                                        Civil engineering
                                        32 000
     2 ultrafiltration modules        227 000
     Accessories and miscellaneous      61 000

                                        Total
                                        320 000  FF (1992)

    Operation and maintenance costs

                                        Energy and reagent
                                        9 200    FF
                                        Maintenance
                                        7 000    FF
     Concentrate transportation        7 200   FF

    Null amortization due to the subsidies received.
                                        Water saving
                                        1 500    FF
                                        Pollution saving
                                        40 500   FF (1992)

    Period of amortization:  2 years.

6.   Advantages:   Suppression of any external discharge and
     any risk of pollution.
     No use for cleaning nor treatment reagent.
     Drinking water resources saving.
     Technique can be reproduced on any ink discharges.

7.   Constraints:  No information provided.

8.   Contacts:

              Agence de l'Eau Adour-Garonne
              M. RAUCOULES
              TEL: 33 61.36.37.38

              M. J.C. RIVES
              PrÆsident Directeur GÆnÆral
              Cartonneries de l'Agenais
              B.P. 11
              82410 VALENCE D'AGEN - France
              TEL: 33 63.39.51.27

              S.A. Cartonnages de l'Agenais
              Chemin d'Orliac
              82400 VALENCE D'AGEN -  France
              TEL: 33 63.39.51.27
              FAX: 33 63.29.18.80

     M. Maton
     M. Chatenet
     Office International de l'Eau
     Direction de la Formation et des Etudes
     rue Edouard Chamberland
     87065 Limoges Cedex, France
     TEL:  33  55114770
     FAX:  33  55777115

9.   Keywords:  France, ISIC 3411, ISIC 3412, ISIC 3420,
     printing, recycling, ultrafiltration, heavy metal,
     membrane, ink, flexographic printing, filtration

10.  This case study was submitted to UNEP IE in 1994 by the
     French Office International de l'Eau. It has not undergone
     a formal technical review.