Production Related Waste Management for Selected Chemical
lchemid=N420
Waste Management Comparison - 2022
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* |
|---|---|---|---|
| 2022 |
Source Reduction:: S21: Optimized process conditions to increase efficiency
|
Methods to Identify SR Opportunities: T04: Participative team management
|
S21: continue to optimize processes to minimize excess materials |
| 2021 |
Source Reduction:: S24: Modified or updated equipment or layout[-0-4%]
|
Methods to Identify SR Opportunities: T04: Participative team management
|
Source Reduction - OPTIMIZE |
| 2020 |
Source Reduction:: W19: Other changes in operating practices[-0-4%]
|
Methods to Identify SR Opportunities: T04: Participative team management
Barriers: B3-Barriers to P2 B3 - Concern that product quality may decline as a result of source reduction. |
Source Reduction - Manufacturing upgrades continue and provide incremental improvements Other Barriers to Source Reduction - Inability to identify a recycling market for scrap solid leaded glass Barriers to P2: B3 - Concern that product quality may decline as a result of source reduction. - Reduced Lead Oxide percentage is not feasible due to rigid specifications |
| 2019 |
Source Reduction:: W58: Other process modifications[-0-4%]
|
Methods to Identify SR Opportunities: T04: Participative team management
Barriers: B3-Barriers to P2 B3 - Concern that product quality may decline as a result of source reduction. |
W58: A series of manufacturing upgrades & improvements have been implemented to provide incremental reductions in scrap / increases in yield. These process modifications include state of the art controls & new centrifuges on CNC machines, new assembly holders, improved annealing & cutting techniques for raw materials and custom extended-length bar stock on the most popular codes. Source Reduction - Facility utilizes a robust Continuous Improvement Program (CIP) to monitor QC and provide daily/weekly manufacturing metrics. Other Barriers to Source Reduction - Inability to identify a recycling market for the scrap leaded glass Barriers to P2: B3 - Concern that product quality may decline as a result of source reduction. - Cannot reduce the Lead (Oxide) percentage of the solid glass bar stock due to rigid product specifications |
| 2018 |
Source Reduction:: W19: Other changes in operating practices[-5-14%]
|
Methods to Identify SR Opportunities: T04: Participative team management
Barriers: B7-Barriers to P2 B7 - No known substitutes or alternative technologies. |
Barriers to P2: B7 - No known substitutes or alternative technologies. - Lead (oxide) percentage is specified by clientVaries with the 40% - 60% rangeLead (oxide) percentage does not affect the scrap rate or production operations |
| 2017 |
Source Reduction:: W19: Other changes in operating practices[-0-4%]
Source Reduction:: W81: Changed product specifications |
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T11: Other |
W19: Nominal improvements to reduce scrap in specific product lines, using standard Quality Control/Quality Assurance methods W81: The percentage of Lead (oxide) in the raw materials changes year-to-year based on client/market demands. The percentage ranges from approximately 40% - 60%. Scrap rate is not affected by Lead constituent level. Source Reduction - Driven by product demand Source Reduction - Quality Control/Quality Assurance team initiated a series of projects designed to improved specific manufacturing steps on specific product lines. |
| 2016 |
Source Reduction:: W81: Changed product specifications
|
Methods to Identify SR Opportunities: T04: Participative team management
|
W81: The percentage of Lead Oxide in the raw material stock changes based on product/customer/market demands. In 2016, more high percentage material was processed than in 2015. However, the facility scrap rate is not impacted by these percentage changes. |
| 2015 |
Source Reduction:: W89: Other product modifications[-15-24%]
|
Methods to Identify SR Opportunities: T04: Participative team management
|
|
| 2014 |
Source Reduction:: W49: Other raw material modifications
|
Methods to Identify SR Opportunities: T04: Participative team management
|
W49: Lead oxide percentage in the incoming glass varies from 40%-60%, depending on customer demands. 2014 yielded more demand for lower % products vs 2013. Manufacturing improvements to optimize the shape of inlet glass bars & blocks are ongoing Other Environmental Practices: Recycling - Efforts continue to identify a recycler for the waste glass. |
| 2013 |
Source Reduction:: W58: Other process modifications
|
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
|
W58: INCOM continues to upgrade milling machines, drawing towers and associated controls to improve production efficiency. Source Reduction - Continuous Improvement Program Other Environmental Practices - Production in 2013 included a higher demand for products that use leaded glass with a higher percentage of lead oxide; 53% & 60% as compared to 40%. The drawing and milling operations generate scrap without regard to changes in the raw material lead oxide content. The resulting increase in lead oxide containing waste offsets progress made in waste reduction.INCOM is actively seeking a recycling market for its' (solid) leaded glass waste stream. |
| 2012 |
Source Reduction:: W49: Other raw material modifications
Source Reduction:: W58: Other process modifications |
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s)
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) |
Source Reduction - During production activities at the drawing towers, INCOM was able to connect two bars end to end. Typically, the largest scrap from the process is in the beginning of a draw and the end of a draw. This joining of two bars end to end increased the time of the run reduced scrap significantly. Reductions are not quite linear as there is some loss for distortion at the bond line. Furthermore, INCOM has been able to purchase 1.5 meter lengths versus the traditional one meter length. These will also allow for longer draws and less scrap. |
| 2011 |
Source Reduction:: W32: Improved procedures for loading, unloading, and transfer operations
Source Reduction:: W52: Modified equipment, layout, or piping |
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management |
W32: Improved techniques for raw material input implemented to reduce scrap and improve yield W52: Updated PLCs, controls, centrifuges and CNC capabilities to reduce scrap and improve yield Source Reduction - A recycling vendor was contracted in 2Q10. Over 120,000 pounds of leaded glass (43,000 pounds of lead compounds) were recycled in 2011. In 2012, this vendor discontinued accepting this waste stream. INCOM actively seeking new vendor to recycle this glass. |
| 2010 |
Source Reduction:: W52: Modified equipment, layout, or piping
|
Methods to Identify SR Opportunities: T04: Participative team management
|
Other Environmental Practices - Implemented recycling program in March 2010 for leaded glass |
| 2009 |
Source Reduction:: W52: Modified equipment, layout, or piping
Source Reduction:: W58: Other process modifications |
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T04: Participative team management |
|
| 2008 |
Source Reduction:: W52: Modified equipment, layout, or piping
Source Reduction:: W58: Other process modifications |
Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program)
Methods to Identify SR Opportunities: T04: Participative team management |
|
| 2007 |
Source Reduction:: W19: Other changes in operating practices
Source Reduction:: W51: Instituted recirculation within a process Source Reduction:: W58: Other process modifications Source Reduction:: W66: Modified or installed rinse systems |
Methods to Identify SR Opportunities: T11: Other
Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program) |
|
| 2006 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
Source Reduction:: W24: Instituted better labeling procedures |
Methods to Identify SR Opportunities: T11: Other
Methods to Identify SR Opportunities: T11: Other |
|
| 2005 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
Source Reduction:: W29: Other changes in inventory control Source Reduction:: W52: Modified equipment, layout, or piping |
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 |
|
| 2004 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
Source Reduction:: W52: Modified equipment, layout, or piping Source Reduction:: W89: Other product modifications |
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 |
|
| 2003 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
Source Reduction:: W52: Modified equipment, layout, or piping Source Reduction:: W89: Other product modifications |
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 |
|
| 2001 |
Source Reduction:: W19: Other changes in operating practices
|
Methods to Identify SR Opportunities: T11: Other
|
|
| 2000 |
Source Reduction:: W19: Other changes in operating practices
|
Methods to Identify SR Opportunities: T11: Other
|
|
| 1999 |
Source Reduction:: W19: Other changes in operating practices
|
Methods to Identify SR Opportunities: T11: Other
|
TRI Pollution Prevention Glossary
The Waste Management Hierarchy |
The waste management hierarchy established by the Pollution Prevention Act (PPA) guides waste generators toward the best options for managing wastes.
The preferred option is to prevent pollution at its source, but for waste that is generated, the preferred management methods are recycling, followed
by burning for energy recovery, treatment and, as a last resort, disposing of the waste.
|
- A breakdown of production-related waste managed. This includes all amounts of the chemical released directly to the environment or otherwise managed as waste, other than waste generated by one-time events not associated with normal production processes (e.g., fires or remedial actions).
- A production ratio or activity index to provide context for reported toxic chemical quantities. For example, if a chemical is used in the manufacture of refrigerators, the production index would track the number of refrigerators produced and could be used to help gauge how much of the chemical is being released per unit of production.
- Any newly implemented source reduction activities, reported using "W-codes" (e.g., "W41: Increased purity of raw materials")