Finance & Administration Directorate - Environmental Management System
PROCESS ASSESSMENT FORM  ID-349-PRT
Issue Date 6/2/00	Rev. 1		Prepared By: EMS Representative
Approved EMS Committee 00/00/00		Approved 0/0/0 through  Rev. 1 by B. Sack, Assistant Laboratory Director for Finance & Administration

I.          General Information 

Process ID:	ID-349-PRT                            PEP = 349
Process Name:	Printing Operations
Process Flow Diagram:	347 PAF DWG 01
Process Description:	This process includes the two Printing Presses located in Building 197B and managed by the Photography and Graphic Arts Section of the Information Services Division at BNL. The Printing presses are fully automated systems, which replenish their inks from reservoirs within the presses.  The systems are washed down after each printing operation is complete.
Aspects:	The significant aspects associated with the operation are industrial waste, hazardous waste, atmospheric discharge, liquid discharges and chemical storage.
Legal Requirements:	Relevant SBMS subject areas include Pollution Presentation & Waste Minimization, Facility Use Agreements, Work Planning & Control, Storage & Transfer of Hazardous Material, Hazardous Waste Management, Sit Emissions, Liquid Effluents and Spill Response.  Other relevant documents include PGA SOPs.
Dept/Div:	Photography & Graphic Arts Division
Dept Code:	PG
Buildings:	197B
Room(s):	N/A
Point of Contact:	R. Backenoff	x 7640
Prepared by:	P. D. Pohlot	Reviewed by:	B. Style	B. Lee
Approved by:			B. Style

 II.        Detailed Process Descriptions and Waste Determination 

The operation of the Printing Presses, located in Building 197B and managed by the BNL Information Services Division has been organized into four components, identified as 1.0 through 4.0. These four components include computer-generated word processing and graphics, transferring text and graphics to film, negative printing plate production and printing. The department operates two presses, a Komori Sprint 26 Press and an AB Dick 9810 Press.  Process Flow Diagrams ID-349-PNT-01 and 02, provided in Attachment 1, graphically depict the inputs and outputs for these two presses.  As shown in the diagrams, the first three components are identical for both presses. 

The first step in the process is computerized preparation of text and graphics.  Formatted pages are transferred to a film sheet using the AGFA SelectSet Avantra 30E, which is an image setter and a fully contained film processing system.  The input and waste streams for this unit can be found in PEP 347.  The resultant developed film sheet is loaded on to the arc lamp table where the image is exposed/burned on to an aluminum offset printing plate with a chemically reactive surface.  The aluminum offset printing plate is then developed by the Encomatic Negative Plate Processor.  The resultant negative image printing plate is attached to either of the  presses to produce the final printed product.  

 Both the Komori Sprint 26 and the AB Dick 9810 are fully automated presses.  The presses utilize rollers to transfer soy based inks to the printing plate, then to a blanket, which then transfers the inks to paper.  The inks used are stored in reservoir within the press.  In order to prevent the inks from piling up on the printing plate (keeping the image and plate clean), fountain solutions are used.  The fountain solution for the Komori Sprint 26 is refrigerated and re-circulated through a self-contained pumping unit.   After two weeks of use the solution is discarded down the sink.  The fountain solution for the AB Dick 9810 is stored in a reservoir and used as needed.  Spent inks from the printing operations are collected and sent to WMD as industrial waste.  The plates are cleaned and either stored or collected and sent to Supply and Materiel for recycling.  Film is saved for reuse, sent out for recycling, or directed to the trash.

Regulatory Determination of Process Outputs

 1.0              Computer Generated Text and Graphics Processing

 None - no waste streams generated.

 2.0              AGFA SelectSet Avantra 30E

See PEP # 347.

 3.0              Negative Plate Processor

Spent developer and finisher are changed out every 6-months and sent to WMD as industrial waste.  Excess/scrap offset printing plates are either sent to a recycler (price dependent) or to the trash. 

 

Waste ID	Waste Description	Determination/Basis	Waste Handling	Corrective Action Required
3.1	Spent developer and finisher	Non-hazardous wastewater as determined by sample analysis and process knowledge	Collected in a 5-gallon drum and sent off-site as industrial waste.	None.
3.2	Scrap offset printing plates	Non-hazardous as determined by sample analysis and process knowledge.	Sent to a recycler or to the trash	None

 4.0              Printing Process

            Komori Sprint 26 and AB Dick 9810 Printing Presses

 

Waste ID	Waste Description	Determination/Basis	Waste Handling	Corrective Action Required
4.1	Waste Ink	Non-hazardous wastewater as determined by process knowledge	Collected in a 5-pound container and sent off-site as industrial waste.	None.
4.2	Spent Blanket Cleaner on wipes	Non-hazardous waste as determined by sample analysis and process knowledge.	Sent to commercial laundry.	None
4.3	Fumes	Non-hazardous vapors as determined by process knowledge.	Vapors vented into the room.	None.
4.4	Paper Towels and empty plastic containers	Non-hazardous waste as determined by individual component	Collected as municipal solid waste.	None
4.5	Roller Cleaner with Absorbent Cotton	Non-hazardous waste as determined by process knowledge.	Sent to trash	None
4.6	Cardboard containers and paper	Non-hazardous recyclable materials.	Recycled	None
4.7	Spent Fountain Solution	Non-hazardous waste as determined by process knowledge.	Directed to sanitary sewer.	None

 

 

III.       Waste Minimization, Opportunities for Pollution Prevention

 

The Information Services Division has implemented numerous waste minimization options to date. These implemented options include:

-         Computerization of input

-         Non-chemical imagery transfer systems

-         Automated photographic processing

-         Continual review of products to minimize use of hazardous products (i.e., soy based inks and aqueous based fountain solutions)

-         Use of recycled paper

-         Reuse of empty product containers to ship off spent or recyclable materials

-         Laundering and reuse of  used rags

 

 

IV.       Assessment Prevention and Control

 

None.