Paint Manufacturing Industry Waste Minimization
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The document discusses waste minimization opportunities and reporting practices in the paint manufacturing industry. It outlines a 5-step waste minimization program that includes conducting an audit to identify waste streams, developing a plan to reduce waste, implementing the plan, and monitoring progress. Various waste reduction, reuse, recycling, and recovery options are presented, such as segregating wastes, implementing quality control, using reusable containers, and blending off-spec products. Success stories from Asian Paints are provided, where waste has been reduced by over 72% through upgraded facilities and innovative processes.
Paint Manufacturing Industry Waste Minimization
- 1. Paint Manufacturing Industry Waste Minimization (Pollution Prevention) Opportunities & Environment Reporting Practices in Paint Manufacturing Industry
- 2. Why Waste Minimization? Waste Minimization Makes Good Business Sense Wastes Costs Money Prices to landfill wastes are steadily increasing Cost for disposal of hazardous wastes are prohibitive to many small businesses Waste Minimization Can Improve Your Public Image Environmental concerns share public spotlight Commitment to environmental issues ca be used as marketing tool for product and services Waste Minimization Can Reduce Your Liability Many legislations impose heavy penalties for non-compliance with waste management legislation
- 3. Success Stories Reuse of Washings in Primer Product As color of the primer is not important, wash wastes are added into the primer without having to segregate colors Hence, no disposal method & transportation costs required Accurate Quality Control Manufacturer uses a sophisticated method of ensuring quality control of the product, which significantly reduces amount of off-spec product Amount of off-spec paint produced has decreased by 50% since the method has been implemented, resulting in greater customer satisfaction & reduced waste management costs
- 4. Waste Minimization Program Step 1: Build Interest Gain support of management and employees Designate a company waste co-ordinator Create your audit team
- 5. Waste Minimization Program Step 2: Conduct a Waste Audit Determine required level of detail Identify process inputs Identify process outputs Identify material destinations Determine material balance Identify raw materials Identify waste disposal costs
- 6. Waste Minimization Program Step 3: Develop a Waste Minimization Plan Identify alternatives Evaluate alternatives Prioritize alternatives Prepare recommended plan
- 7. Waste Minimization Program Step 4: Implement Your Plan Develop implementation schedule Obtain approval to proceed Inform and train staff
- 8. Waste Minimization Program Step 5: Monitor Progress Document waste quantities and costs Maintain dialogue with suppliers Review operations
- 9. Waste Minimization Options Waste minimization involves the application of 4 R’s: R educe (at point of generation) R euse (for the same purpose or for other purpose) R ecycle (reprocess to re-establish usefulness) R ecover (energy from waste, reclaim items of value, or remove hazardous components prior to disposal) Through proper management (treatment and disposal), the quantities of waste streams generated and the associated costs of disposal can be minimized.
- 10. Waste Minimization Options R educe Waste Minimization Option All waste streams Segregate wastes according to characteristics Implement an inventory control system to prevent unnecessary purchases Assign responsibility of waste management budgets to the departments generating the wastes Off-Spec Product Implement quality control systems
- 11. Waste Minimization Options R educe Waste Minimization Option Volatile Organic Compounds (VOCs) Install airtight covers on mixing vessels Install floating lids on solvent storage containers Keep all solvent containers sealed at all times Substitute with non-VOC cleaning solvents where practical Dust Purchase powders in a paste form to eliminate dust
- 12. Waste Minimization Options R educe Waste Minimization Option Wash-water, Wash-solvent, & Wash-solids Schedule long production runs of one color Schedule production runs from light colors to dark colors Install high pressure, low volume spray nozzles Allow sufficient time for washwater clarification Line mixing vessels with non-stick surfaces and mechanical scrapers / rubber wipers
- 13. Waste Minimization Options R educe Waste Minimization Option Raw Material Packaging Purchase powders in water soluble containers Purchase materials in bulk, rather than drums to decrease evaporative losses Compact non-recyclable and non-reusable containers to save on disposal charges
- 14. Waste Minimization Options R euse Waste Minimization Option Filters Use reusable wire mesh screens Raw Material Packaging Advertise and obtain used pallets Establish container cleaning contracts where practical Obtain materials in returnable containers
- 15. Waste Minimization Options R ecycle Waste Minimization Option Rags Consider a rag cleaning service Raw Material Packaging Consign paper bags to paper recycler, shrink wraps to a recycler and waste metal cans to a metal recycler Off-spec Product Blend off-spec products and old samples with new product Wash-water, Wash-solvent, and Wash-solids Recycle washings as a component for a primer product Purchase reconditioned solvents for cleaning purposes
- 16. Waste Minimization Options R ecover Waste Minimization Option Volatile Organic Compounds (VOCs) Install VOC recovery units on ventilation units Raw Material Packaging Repair broken pallets or offer to employees and public as firewood Dust Install a dust collection system in ventilation systems
- 17. Asian Paints - Success Asian Paints Limited takes up the environment issue from the perspective of waste minimization and conservation of resources. It makes a continued attempt to reuse, recycle and eliminate waste, which results in a diminished amount of waste being generated. It has succeeded at building synergy between business and environment which has enabled it to follow the path of profit-making along with growth for sustainable development. It has succeeded at driving eco-friendly initiatives using environment management systems and thereby diminishing the impact on the environment. The bulk storage facilities have been upgraded thereby reducing material losses as well as eliminating effluent generation.
- 18. Asian Paints - Success Asian Paints Limited has been among the forerunners in adapting principles of 'Green Productivity'. Plants have achieved ' zero industrial discharge ' capability by installing upgraded effluent treatment facilities and setting up plants in accordance with appropriate recycling & reuse schemes working towards substantially reducing material losses. Company's emulsion manufacturing facility has also achieved ' zero waste ' status . Innovations in filtration process technology have resulted in higher filtration rates and lower losses and, consequently lesser pollution. Company has also reduced waste by over 72 % after upgrading incinerating systems. The rest of the waste is re-used.