Division of Pollution
Prevention and
Environmental
Assistance
Industrial Assistance Section
John Burke 336-249-1480
www.p2pays.org
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
Conducting a Solid Waste
Reduction Assessment
http://www.p2pays.org/ref/01/00833.pdf
Section 3 page 65
Steps
Preparation
 Opening meeting
 Walk through
 Closing meeting
 Final report
 Follow-up

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)
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
Fiber Glass Pipe
Labor
11%
Disposal
3%
Material
86%
Cost of Waste
$1.443 million a year
Waste Management Hierarchy
Source
Reduction
Direct Reuse
On-site Recycling
Off-site Recycling
Treatment & Disposal
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)
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
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

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

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
Case Study

Packaging redesign
–
–
–
–
Company:
Product:
Problem:
Solution:
– Savings:
Eagle Snacks, Robersonville
snack foods (potato ships, nuts)
costs for packaging materials
reduce layers of bags from 5 to 3
reduce thickness of steel cans
500 tons / yr of plastic
225 tons / yr of steel
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
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”
Case Study

Production waste
– Company:
– Problem:
– Causes:
Wasted Synthetic Paper
Synthetic paper manufacturer
1.4 M lbs of product waste / yr
Poor training, operational
control
t
g wavy paper
or damaged ends
p
it n
a
ns damaged surface
co roll too tight tra
n
ki
light paper jamming
g
p
t-u
ac
st
ar
st
- Savings:
setting blades
Revenue increases of +150,000/yr for
25% reduction in wasting
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”
The Cost of Waste
Raw Material
 Labor
 Disposal
 Waste Handling

– Physical
– Administrative
Truck Liner Manufacturer
4.86 pounds
Plastic 2% loss allowance
4.96 pounds - 2 parts
Sheet
0.10 pounds waste
Oven
2.30 pounds
Carpet
2.66 pounds
Waste
Press
Parts
Rooney, Charles “Economics of P2: How Waste Reduction Pays”. Pollution Prevention Review, Summer 1993
Pressed Plastic Parts
Labor
Disposal
3%
3.5%
2.75 million/yr
4.30 million/yr
Material
93.5%
Cost of Waste
Cost of Plant Labor
Rooney, Charles “Economics of P2: How Waste Reduction Pays”. Pollution Prevention Review, Summer 1993
Other Areas

Cafeteria/break rooms
– Food waste handling
– Utensils
– Recycling containers

Office Areas
– Purchasing specifications
– Recycling containers
Other Areas
Disposal
 Laboratory
 Production maintenance
 Vehicle maintenance
 Quality control / assurance
 Utilities (boilers, compressors)
 Bag houses
 Waste treatment

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.

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

Waste
Straps (suppliers)
Straps (sister facilities)
Bale Wraps
Poly Bags (25 cents/lb)
Sleeving
Plastic Sheeting
Cardboard (from suppliers)
Disposable Dye Springs
Wasted Fiber, Virgin
Wasted Fiber, Dyed
Pallets***
Demolition (equipment/buildings)**
Packaging material
Kraft Paper
Paper Board Dividers
Paper Cones (0.05 lbs/cone)
Wax
Cardboard (for packaging)
Total
Estimated Total Landfilled*
Estimated
Total Volume
Entering
Plant,
lbs/year
Estimated
Material
Wasted, %
Estimated
Volume of
Material
Landfilled,
lbs/year
Estimated Estimated
Disposal Material
Costs,
Costs,
$/year
$/year
13,000
15,000
26,500
23,548
20,000
11,804
1,250,000
800,000
1,000,000
500,000
100%
100%
10%
100%
100%
100%
15%
2%
2%
2%
13,000
15,000
2,650
23,548
20,000
11,804
187,500
16,000
20,000
10,000
88,000
66,880
$569
$656
$116
$1,030
$875
$516
$8,203
$700
$875
$438
$3,850
$2,926
?
?
?
$5,887
$30,000
$6,900
?
?
?
?
?
?
28,000
205,360
1,450,000
169,544
??
20%
10%
2%
20%
1%
5,600
20,536
29,000
33,909
?
$245
$898
$1,269
$1,484
?
$2,600
$9,700
$1,700
$46,000
?
563,427
1,760,000
$24,650
$77,000
$102,787

Improve winding
operation to reduce
wasted fiber through
training and
awareness or
increased
automation.
Yarn, lbs/day
Total Wasted,
%
Usable Portion
of Wasted
Yarn, %
Value of
Product Yarn,
$/lb
Value of
Wasted Yarn,
$/lb
Estimated lost
value, $/year
500,000
2%
5%
$
1.50
$
0.25
$ 162,500.00
Waste
Straps (suppliers)
Straps (sister facilities)
Bale Wraps
Poly Bags (25 cents/lb)
Sleeving
Plastic Sheeting
Cardboard (from suppliers)
Disposable Dye Springs
Wasted Fiber, Virgin
Wasted Fiber, Dyed
Pallets***
Demolition (equipment/buildings)**
Packaging material
Kraft Paper
Paper Board Dividers
Paper Cones (0.05 lbs/cone)
Wax
Cardboard (for packaging)
Total
Estimated Total Landfilled*
Estimated
Total Volume
Entering
Plant,
lbs/year
Estimated
Material
Wasted, %
Estimated
Volume of
Material
Landfilled,
lbs/year
Estimated Estimated
Disposal Material
Costs,
Costs,
$/year
$/year
13,000
15,000
26,500
23,548
20,000
11,804
1,250,000
800,000
1,000,000
500,000
100%
100%
10%
100%
100%
100%
15%
2%
2%
2%
13,000
15,000
2,650
23,548
20,000
11,804
187,500
16,000
20,000
10,000
88,000
66,880
$569
$656
$116
$1,030
$875
$516
$8,203
$700
$875
$438
$3,850
$2,926
?
?
?
$5,887
$30,000
$6,900
?
?
?
?
?
?
28,000
205,360
1,450,000
169,544
??
20%
10%
2%
20%
1%
5,600
20,536
29,000
33,909
?
$245
$898
$1,269
$1,484
?
$2,600
$9,700
$1,700
$46,000
?
563,427
1,760,000
$24,650
$77,000
$102,787

Reduce
processing aids
through
process
modifications
and increased
controls
Current W ax Disc
New Wax Disc
2
1
3
2
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

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