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Facility ID: 06001RFLXT120DA

Facility Name and Address:
 ORAFOL AMERICAS INC
120 DARLING DR
AVON, CT 06001

Parent Company: ORAFOL INTERNATIONAL

Industry: Commercial Gravure Printing (323111)
Chemical: Toluene

Reports:
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Production Related Waste Management for Selected Chemical


Show P2 data for other chemicals at this facility:
lchemid=0000108883
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Pollution Prevention Activities for Selected Chemical

Reporting Year Section 8.10: Newly Implemented Source Reduction Activity Section 8.10: Methods to Identify Activity Section 8.11: Optional Pollution Prevention Information*
2024 Source Reduction:: S12: Altered dimensions, components, or final design of product
Source Reduction:: S24: Modified or updated equipment or layout
Source Reduction:: S33: Improved containment or material handling operations
Source Reduction:: S34: Improved monitoring practices of potential spill or leak sources
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
S12: Adding longer roll lengths. 300 and 450 feet
S24: New heat sealer equipment and Titan control improvements.
S33: Chemical pumps for coating and casting lines. Reduction of potential spills/spills.
S34: Spring valves/overflow indicators on sonic wash reducing waste.
2023 Source Reduction:: S11: Reformulated or developed new product line[-0-4%]
Source Reduction:: S21: Optimized process conditions to increase efficiency[-0-4%]
Source Reduction:: S33: Improved containment or material handling operations[-0-4%]
Source Reduction:: S41: Improved scheduling, record keeping, or procedures for operations, cleaning, and maintenance[-0-4%]
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
S11: 2023- Pre-laminated Marathon project, New orange fire tape with 1-pass RSP for diamond plate instead of previous 2-pass process.
S21: 2023- Titan slitter shafts / firetape slitting bar-complete, larger Super Bright die-complete. Change 5934 carrier from 2 mil to 142 gauge to reduce cost/waste.-This is done for both 5934 white and orange.
S33: 2023-Spring valves to prevent leaks- completed2023- Pumps/pans for coating lines- capturing leaks/failures-completed.
S41: 2023- 5S program. Monitoring maintenance activities through televisions/spreadsheets. Training complete-material flow request screen install in logistics/conversion area. Complete in Logistics. Using monitor on computer in conversion.
2022 Source Reduction:: S25: Other process modifications made[-0-4%]
Source Reduction:: S41: Improved scheduling, record keeping, or procedures for operations, cleaning, and maintenance[-0-4%]
Source Reduction:: S44: Other improvements to operating practices and training[-5-14%]
Source Reduction:: S03: Substituted raw materials, feedstock, or reactant chemical[-100%]
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
S41: purchase of new equipment reducing water usage and sonic cleaner material- sonic washer replaced.
S44: New SB roll up sign die. 10% through put improvement.

Source Reduction - implemented plastic banding instead of metal banding- process eliminated steel scrap
Source Reduction - Fire Foam Replacement
2021 Source Reduction:: S13: Modified product packaging[-50-99%]
Source Reduction:: S21: Optimized process conditions to increase efficiency[-0-4%]
Source Reduction:: S35: Other improvements to inventory and material management[-5-14%]
Source Reduction:: S43: Introduced in-line product quality monitoring or other process analysis system[-5-14%]
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
S13: 50% reduction from Herculite backing for roll sign material coming in racks instead of endboarding
S21: Caster 13 monitor, speed improvement
S35: Have cleaned out materials not in use anymore. Exchange of materials not in use.
S43: Reduction of inbound chemicals reducing waste
2020 Source Reduction:: W14: Changed production schedule to minimize equipment and feedstock changeovers[-0-4%]
Source Reduction:: W22: Began to test outdated material - continue to use if still effective[-5-14%]
Source Reduction:: W15: Introduced an in-line product quality monitoring or other process analysis system[-0-4%]
Source Reduction:: W50: Optimized reaction conditions or otherwise increased efficiency of synthesis[-5-14%]
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management
W14: Longer Runs
W15: Reduction of inbound quality testing of chemicals reducing waste
W22: Testing aged inventory. Eliminated old inventory so we won't be producing as much scrap. Test group eliminated.
W50: Softener system installed in water system eliminating city water consumption

Source Reduction - We meet as a group to continually discuss and review potential source reduction and waste minimization activities.



Source Reduction: Methods for Identifying Pollution Prevention Opportunities - We meet as a group to continually discuss and review potential source reduction and waste minimization activities. Continuously walking the floor auditing and pursuing conversations. Assurance of no PFAS chemicals.

Other Environmental Practices: Recycling - Blades recycled as scrap metalPurchased drum crusher for 2021 implementation

Source Reduction: Source Reduction - W21-product discontinuationW25-recycling / reuse relationship with current vendors for end boards, skids, etc.W29-old inventory sent to sales to clear shelves of old logosW32-transfer vessels to pump from drums to boothW33-installed overflow alarmsW39-new RCRA floor in Chem Mix areaW51-water systemW54 and T10-tote recycling/return

Other Environmental Practices: Waste Treatment - Softener system installed reducing city water consumption and use

Other Environmental Practices: General Environmental Management - Priced outdoor cover for potential use to store pallets underneath and apply for no-exposure certification for SW mgmt. New RCRA Floor in Chem Mix area
2019 Source Reduction:: W43: Substituted a feedstock or reagent chemical with a different chemical[-100%]
Methods to Identify SR Opportunities: T04: Participative team management
W43: Formulation changes to eliminate REACH materials
2018 Source Reduction:: W14: Changed production schedule to minimize equipment and feedstock changeovers[-5-14%]
Source Reduction:: W82: Modified design or composition of product[-5-14%]
Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program)
Methods to Identify SR Opportunities: T04: Participative team management
W14: Scheduling process changes to reduce the number of changeovers and associated waste (increased batch size).
W82: Components moving away from using toluene as the primary solvent.
2017 Source Reduction:: W49: Other raw material modifications[-5-14%]
Methods to Identify SR Opportunities: T04: Participative team management
W49: Eliminated the use of raw toluene in favor of a pre-mixed solvent blend; reducing air emissions due to mixing. Eliminated a chemical composition which was higher in toluene.
W49: Eliminated the use of raw toluene in favor of a pre-mixed solvent blend; reducing air emissions due to mixing.
2016 Barriers: B6-Barriers to P2 B6 - Pollution prevention previously implemented - additional reduction does not appear technically or economically feas

Barriers to P2: B6 - Pollution prevention previously implemented - additional reduction does not appear technically or economically feas - Reduction in process waste conducted during prior reporting year and continues through this reporting year.
1994 Source Reduction:: W23: Eliminated shelf-life requirements for stable materials
Source Reduction:: W61: Changed to aqueous cleaners (from solvents or other materials)
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program)
*Classifications of Optional Pollution Prevention Information shown in brackets are provided by EPA.