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Division of Pollution Prevention and Environmental Assistance

Get free, non-regulatory on-site technical assistance to achieve compliance, reduce waste management costs, and increase production efficiency. Available in air, water, and solid waste areas.

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Division of Pollution Prevention and Environmental Assistance

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  1. Division of Pollution Prevention and Environmental Assistance Industrial Assistance Section John Burke 336-249-1480

  2. www.p2pays.org

  3. On-site Technical Assistance • Free • Non-regulatory • Multimedia (air / water / solid waste) • Areas of assistance • Achieving compliance • Reducing waste management costs • Increasing production efficiency • Developing environmental management systems

  4. Conducting a Solid Waste Reduction Assessment http://www.p2pays.org/ref/01/00833.pdf Section 3 page 65

  5. Steps • Preparation • Opening meeting • Walk through • Closing meeting • Final report • Follow-up

  6. Assessment Preparation • Obtain summary information • What company does and major solid waste issues • Request attendees for opening meeting • Environmental manager, production manager, and maintenance manager • Background research on industry • Online research (p2pays.org references)

  7. Background Information • Monthly tonnage • Monthly tipping fee • Monthly hauling fee • Monthly rental fee • Solid waste containers • #, size, and average tonnage • Labor costs (waste handling) • Current recycling/reuse program data • Scrap rates and purchasing data

  8. Cost of Waste $1.443 million a year

  9. Source Reduction Direct Reuse On-site Recycling Off-site Recycling Treatment & Disposal Waste Management Hierarchy

  10. Assessment Preparation • Obtain summary information • What company does and major solid waste issues • Request attendees for opening meeting • Environmental manager, production manager, and maintenance manager • Background research on industry • Online research (p2pays.org references)

  11. Opening Meeting • Facility layout and operations overview • Current recycling programs and solid waste management programs • Is there a waste reduction team or other team? • How are employees trained and informed? • Is there an employee suggestion program? • Are there goals established? • Review of cost data • New projects or failed projects related to waste reduction

  12. Walk Through • Consider starting out with “dumpster dive” and tour of recycling area. • Follow flow of material through production from receiving to shipping. • Request supervisor of department to provide overview. • Approach employees for specific areas where waste are generated or handled. • Look in recycling and disposal containers

  13. Walk Through • Consider starting out with “dumpster dive” and tour of recycling area. • Follow flow of material through production from receiving to shipping. • Request supervisor of department to provide overview. • Approach employees for specific areas where waste are generated or handled. • Look in recycling and disposal containers

  14. Material Receiving / Storage / Shipping • Practices that cause damage or spoilage • Opportunities for to reduce, reuse or recycle packaging • Packaging redesign • Bulk containers for high use materials • Reuse of pallets, boxes, sacs for in plant distribution or shipping • Packaging return programs

  15. Case Study • Packaging redesign • Company: Eagle Snacks, Robersonville • Product: snack foods (potato ships, nuts) • Problem: costs for packaging materials • Solution: reduce layers of bags from 5 to 3 reduce thickness of steel cans • Savings: 500 tons / yr of plastic 225 tons / yr of steel

  16. Material Receiving / Storage / Shipping • Practices that cause damage or spoilage • Opportunities for to reduce, reuse or recycle packaging • Packaging redesign • Bulk containers for high use materials • Reuse of pallets, boxes, sacs for in plant distribution or shipping • Packaging return programs

  17. Production • Waste generated from start-up, shut down, change-over. • Waste generated from continuous operations edge trim, machining, etc. • Locations and labeling of recycling containers. • Handling of off-spec materials • Monitoring of waste volumes (80/20 rule) • Identify “True Cost of Wasting”

  18. Case Study • Production waste • Company: Synthetic paper manufacturer • Problem: 1.4 M lbs of product waste / yr • Causes: Poor training, operational control - Savings: Revenue increases of +150,000/yr for 25% reduction in wasting

  19. Production • Waste generated from start-up, shut down, change-over. • Waste generated from continuous operations edge trim, machining, etc. • Locations and labeling of recycling containers. • Handling of off-spec materials • Monitoring of waste volumes (80/20 rule) • Identify “True Cost of Wasting”

  20. The Cost of Waste • Raw Material • Labor • Disposal • Waste Handling • Physical • Administrative

  21. Truck Liner Manufacturer 4.86 pounds 2% loss allowance 4.96 pounds - 2 parts 0.10 pounds waste 2.30 pounds 2.66 pounds Rooney, Charles “Economics of P2: How Waste Reduction Pays”. Pollution Prevention Review, Summer 1993

  22. Pressed Plastic Parts Labor 3% Disposal 3.5% 2.75 million/yr 4.30 million/yr Material 93.5% Cost of Plant Labor Cost of Waste Rooney, Charles “Economics of P2: How Waste Reduction Pays”. Pollution Prevention Review, Summer 1993

  23. Other Areas • Cafeteria/break rooms • Food waste handling • Utensils • Recycling containers • Office Areas • Purchasing specifications • Recycling containers

  24. Other Areas • Disposal • Laboratory • Production maintenance • Vehicle maintenance • Quality control / assurance • Utilities (boilers, compressors) • Bag houses • Waste treatment

  25. Closing Meeting • Praise existing programs and efforts at waste reduction. • Discuss areas where the team sees potential for improvements opportunities. • Request additional information that will be required to develop report.

  26. Final Report • Provide description of operations • Develop best estimate of waste stream analysis and associated cost • Develop true cost estimates for selected waste streams • Discuss technologies and techniques for reducing or reusing waste streams • Provide listing of markets for recycled materials

  27. Improve winding operation to reduce wasted fiber through training and awareness or increased automation.

  28. Reduce processing aids through process modifications and increased controls

  29. Steelfab • Fabricates and coats structural steel • Potential liability and new air permits • Reduced coatings by 50% and used three coatings on 95% of orders • Trained estimating engineers and purchasing agents on benefits of using selected coating systems. • Required approval of environmental personnel prior to issuing bid

  30. Steelfab • Reduce VOC/HAP emissions • Reduce coating system change-outs /cleanup • Reduce use of MEK • Reduce production time and man-hours • Reduce training requirements for painters • Reduce purchasing requirements and problems dealing with multiple coating suppliers • Lower total contract costs to customers

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