MINIMIZING WASTE THROUGH GOOD MAINTENANCE AND HOUSEKEEPING PRACTICES

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1 BEST S SAFETY DIRECTORY EPRIN 1994 EDIT!ON -2 G 7 P S / 25dcli f3/= MINIMIZING WASTE THROUGH GOOD MAINTENANCE AND HOUSEKEEPING PRACTICES vv aste reduction has been a hot topic since the passage of the Hazardous and Solid Waste Amendments of and with good reason: The amount of solid waste generated continues to increase as the number of active landfills decreases. Forty-five percent of the approximately 6,000 landfills are expected to close over the next few years. The Environmental Protection Agency s (EPA) recent moratorium on hazardous waste incinerators makes the picture even gloomier. While landfills close and the number of incinerators remain stagnant, the United States continues to generate over 12 billion tons of non-hazardous solid waste and roughly 300 million tons of hazardous waste annually. The bulk of this waste is generated by industry. Industrial generators of all sizes are faced with the challenge of reducing waste. Rising disposal costs, cradleto-grave liabilities, and societal pressures are forcing many companies to adopt aggressive programs to reduce solid waste. While some KATHLEEN CHOVIT MARK WOYTOWICH Technical Marketing Group New Pig Corporation Tipton, PA large companies have launched highly sophisticated programs with reported success, the use of god operating and housekeeping practices in firms of all sizes can significantly decrease the amount of waste generated. Good operating practices are typically inexpensive and easy to implement. Identifying Good Waste Minimization Practices Identifying effective operating practices, to minimize waste generation does not always require a pro- ing in significant savings for a company. Involving Employees in Waste Minimization Programs Involving employees in the identification and reduction of waste is an excellent way to tap the knowledge and experience of those closest to common waste streams. In fact, involving employees is vital to the success of a waste reduction program. Other key elements of success include: While landfills close and the number of incinerators remain stagnant, the United States continues to generate over 12 billion tons bf non-hazardous solid waste and roughly 300 million tons of hazardous waste annually. The bulk of this waste is generated by industry. cess engineer. Many waste reduction opportunities can be identified by a simple walk-through examination of a plant. For example, a common housekeeping practice used for decades in industrial facilities is spreading clay pellets or kitty litter to clean up waste fluids. Eliminating this practice will decrease the volume of hazardous waste generated, result- 1. upper management support for a waste minimization program; 2. the formation of a waste minimization team; and 3. a plant-wide waste stream assessment by the team. Ideally, each team should include employees responsible for environmental compliance, waste disposal, purchasing, waste manage-

2 ment, and, when necessary, a process engineer. Process engineers are required to modify waste streams created in a manufacturing process. However, opportunities with high impact are often small, low- tech efforts easily identified by those closest to the waste, including maintenance, housekeeping, and manufacturing crews. Reducing Waste Waste can be reduced using three basic methods: 1. reduction of waste at its source; 2. waste segregation; and 3. recycling or reuse. However, the best method of managing waste is to prevent its creation when possible. Pollution prevention methods, as well as waste minimization methods, should be applied company-wide. These methods do not always require sophisticated procedures, as the specific practices which follow will show. Using Contained Absorbents to Reduce Solid Waste Clay pellets (or kitty litter ) are commonly used to respond to leaks and spills of hydraulic Sluids, lubricants, cutting fluids, coolants, and other petroleum byproducts. A close examination of this practice is warranted for waste reduction to be realized. Clay pellets work poorly as an absorbent, picking up as little as 50 percent of their weight in liquid. It makes sense to replace the use of clay with contained absorbents in the form of mats, socks, pads, pillows, and pans. Products made of cellulose, polypropylene, and polyethylene typically can absorb up to 20 times more than clay. The replacement of clay with contained absorbents provides opportunities to: 1. significantly reduce the volume of waste generated; 2. reuse or recycle the absorbents; 3. reclaim or segregate waste liquids, such as oil. Providing routine maintenance on machines to reduce or eliminate oil leakage is the ultimate form of source reduction. For leakage which cannot be eliminated, absorbents with high absorbency ratios will help to reduce waste by a minimum of 50 percent when replacing clay pellets. Highly absorbent materials, such as cellulose, polypropylene, and polyethylene should also be used for spill cleanup.... IBSOR8f T T 1 T c WASTE MlNlMlZATlON WITH CONTAINED ABSORBENTS RECLAIM LlWlD OW RECLAIMED LIQUID Figure 1: This chart illustrates waste reduction alternatives with contained absorbents. Segregating and Recycling of Liquids with Contained Absorbents Reduction of waste oil and the segregation and recycling of wastes depends on which types of absorbents are used (see Figure 1). There are three types of absorbents available: 1. Conventional. Dispose of saturated absorbent. 2. Wringable. Liquids may be reclaimed before disposal of used absorbent. 3. Reusable. Liquids may be reclaimed and the absorbent reused. Both wringable and reusable absorbents are engineered to release absorbed liquid, such as oil, when pressure is applied. However, wringables are disposed of after a single use and reusables may be used again, some up to 17 times. Both types of absorbents allow the segregation of used oils for less costly disposal, reuse, or recycling. Separating used oil from a wringable absorbent reduces the amount of solid waste produced by allowing more absorbents to fit in a drum. Reusable absorbents can reduce solid waste even further, allowing reclamation of up to 90 percent of liquids, and reuse approximately ten times (see Figure 2). The use of a hydraulic compactor 2

3 I (see Figure 3) will allow liquid from solid Waste segregation even with conventional absorbents. By compacting spent absorbents collected in 55-gallon steel drums, liquids can be siphoned into another container with an air pump. Most compactors require the use of specially-designed 55-gallon drums with faucets at the base to allow liq- uid to drain off. The use of this type of compactor defeats waste minimization goals by requiring additional 55-gallon drums with faucets. The model shown in Figure 3 siphons from the top and requires only standard 55-gallon steel drums. The use of the compactor also reduces the number of drums of solid waste going to landfills and incinerators. In some cases, the contents of up to five drums can fit into one drum when compacted. Realizing Cost Savings with Contained Absorbents Money can actually be saved with a good waste minimization program. Clearly, using contained absorbents rather then clay granules will reduce ~~~ WASTE MINIMIZATION IN ACTION A Look at How Owens-Corning Uses Total Quality Management to Minimize Waste With the passage of the Hazardous and Solid Waste Amendments of 1984, hazardous waste generators and small quantity generators have been required by EPA to sign a certification on each manifest [RCRA, Section 3002(b), The generator certifies that they have...a program in place to reduce the volume and toxicity of waste generated... to the extent found economical and practical. As a result, waste minimization has become a widespread goal in industry. Many large companies have launched sophisticated programs to minimize waste. However, the most impactproducing opportunities are often achieved through smaller, low-tech efforts and by involving employees directly in the process. Here is how Owens-Corning successfully achieved waste minimization. Owens-Corning enlisted the help of an Employee Involvement Team and involved all of the company s 73 employees in a successful campaign to reduce, collect, and dispose of waste more efficiently. Employee Involvement Teams are an important part of our Total Quality Management (TQM) approach, explains Joe Kaplan, Environmental Coordinator at the Duncan plant. However, until a year ago, we had never tried using TQM to approach environmental and waste monitoring issues. After our first effort this year, we re very happy with the results. The plant in Duncan manufactures specialized equipment for other Owens-Corning facilities worldwide. In the course of fabricating parts and equipment, significant amounts of coolant, oil, and solid waste are generated. Joe says, It s my job to keep a handle on all of it, make sure we stay in compliance, and keep the plant safe. Owens-Corning s comprehensive enyironmental policy played a role in Joe s formation of an Environmental Employee Involvement Team in November Joe used standard Total Quality Management guidelines for developing his team. The Team s goals were to review the company s waste streams, recommend collection and disposal methods, and implement the program. The waste streams included used machine coolant; used machine oil; dirty mop water contaminated with oil and coolant; solid wastes, such as absorbent socks, mats, and rags; and liquid wastes squeezed from the absorbents and other solids. The team of volunteers - including Owens-Corning employees Mike Dieska, Randy Clair, Marty Fisher, Earl Tyner, and Jeff Lanier - plus Joe met weekly and discussed the waste collection and disposal issues. After examining the facility s operations, the Team identified 16 individual wastes and was able to consolidate the list to four general waste streams: coolant, oil, solid waste, and trash. Consolidating our wastes helped us minimize the steps required to handle it through to disposal, Joe says. One of the Team s first recommen- dations was to purchase a wringer and construct a wheeled cart for reusable absorbents. After we started using the wringer, we developed a wheeled cart to hold the wrung-out absorbents for future use, Joe explains. The wringer allows the employees at Owens-Corning to use absorbents several times before disposal, with the added benefit of used coolant and oil recovery. To handle collection and disposal of wastes, the Team designated a central collection area with three drums to capture coolant, oil, and contaminated solid waste. Accurately segregating coolant and oil is especially important because mixed liquids can t be recycled, Joe says. Plus, recycling services won t accept a mixture of liquid wastes. The Team also helped identify recycling opportunities, including a collection program for cardboard boxes. Now all the employees are more conscious of waste reduction and recycling issues. Joe states that a week does not go by without someone approaching him or a Team member with a waste-related question. For companies interested in pursuing similar programs, Joe recommends first getting the support of management for employee-based decision making. If teams make recommendations, management must be prepared to accept them. When it comes to environmental issues such as waste collection and disposal, a grass roots approach makes sense. The employees on the floor are the ones handling the waste. The way to success is to have lots of pairs of eyes looking for problems and solutions - not just one. 3

4 costs, as well as wastes, in the following ways: (1) Reclaiming liquids saves money. If liquids are reused, initial purchases are reduced. If liquids are able to be recycled, disposal costs are saved. Disposal costs are also decreased by segregating liquids from solids, In sharp contrast, liquids cannot be recaptured when clay is used. (2) Reuse of absorbents saves money. By either wringing or compressing reusable absorbents only once, a plant manager can decrease his upfront absorbent purchase costs by approximately 40 percent. An additional savings can be realized by cutting disposal costs in half - at minimum. Clay cannot be reused; it is expensive to dispose of because it is heavy and does not burn. While the purchase cost of cla; appeais less than most contained absorbents, it is clear that considerable costs are hidden. (3) Use of contained absorbents saves money by reducing the waste volume for disposal. Even the use of conventional (nonwringable and non-reusable) contained absorbents can significantly Seven ways to cut waste and boost profits You can increase profits through an effective waste minimization program. Here are seven ways for you to decrease your hazardous waste: (1) Perform a waste audit. Find out what types and how much waste you are producing. Audits identify waste-producing processes. (2) Develop management initiatives. Encourage employees input by offering incentives for suggestions on waste minimization techniques. (3) Improve housekeeping. This is an inexpensive but effective means of waste minimization and can include proper labeling, storage, disposal, and/or segregation of wastes. (4) Substitute materials. Certain raw materials may produce hazardous waste. Sometimes substitute materials can lead to less toxic or non-toxic wastes which can reduce disposal costs. (5) Redesign equipment. Old equipment and processes often produce more waste than newer ones. Repair, redesign, or replacement of old equipment will often result in higher efficiencies and reduced waste generation, decreased disposal costs, and reduced raw material costs. (6) Reclaim, recycle, reuse wastes. Many wastes can be recycled within the production process, used as fuel, or sometimes sold to other Zompanies. (7) Participate in wmte exchanges. One person s waste can be mother s resource. Waste ex- :hanges are formed by companies seeking markets for their waste and I new source of raw materials. Figure 2 Reusable absorbents enable you to recapture liquids and decrease solid waste Figure 3: This compactor uses a standard 55-gallon drum and tilts back for easy loading, 4

5 , redule the volume of waste in comparison to using clay. Contained absorbents absorb more and weigh less, thus reducing the waste volume for disposal. (4) Use of burnable contained absorbents reduces disposal liability. There are only two basic methods of hazardous waste disposal available - either bum it or bury it. Contained absorbents with high BTU value and low ash content will cost less than clay to burn. Although some incin- Good Operating Practices erators will accept clay, they still must landfill it after the liquid it contains is burned off. The consequence of using clay is higher liability and double disposal costs in some situations. Summary Despite large amounts of money being spent on waste minimization programs, some of the fastest, most cost-effective results can be achieved by the maintenance and housekeeping departments. Environmental Good operating practices in- thereby reducing solid waste clude the following: volume. (1) Formalized waste reduction (4) Cost accounting practices programs should be established should track and allocate the costs and supported by management. of waste generation to waste pro- (2) Proper material handling and ducing departments. This provides inventory practices should be in incentives to reduce these costs, place (Le., preventing accidental when possible, by the generating mixing of hazardous and non- departments. hazardous wastes). (5) After waste streams have been (3) Leaks from equipment should reduced, recycling is the next step be eliminated where possible. Ab- to waste reduction. Opportunities sorbents with high absorbency should be assessed for each waste ratios should be used to respond stream. to unavoidable leaks and spills, compliance can cost money but, conversely, can also make good business sense. A company can actually decrease its costs by eliminating waste at its source and by reducing the production of waste. Reducing or eliminating the use of clay in industrial facilities is a simple and effective method of managing and minimizing waste generation. Using contained absorbents to improve housekeeping practices will decrease waste production while reducing costs. The advent of contained absorbents has arrived as a result of a national agenda to reduce the generation of hazardous waste. Maintenance and housekeeping departments can have a significant impact on minimizing waste streams. By involving employees, the knowledge and experience of many people can be applied to minimizing waste and costs at your facility. 0 REFERENCES Report to Congress; Solid Waste Disposal in the United States, United States Environmental Protection Agency, EPN530-SW Vol. I (October 1988). The Hazardous Waste System, United States Environmental Protection Agency. EPN870-HW ES-2 (June 1987). 5

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