Press cleaning materials are often overlooked as a small cost but, with a rise in short-run jobs, many printers now find that cleaning is a major part of the working day and the volume of cleaning materials used is increasing.

Press cleaning materials are often overlooked as a small cost but, with a rise in short-run jobs, many printers now find that cleaning is a major part of the working day and the volume of cleaning materials used is increasing.

■ the volume of cleaning materials used is increasing

■ the volume of cleaning materials used is increasing.

■ the volume of cleaning materials used is increasing.

Keeping the lidon cleaningmaterials

Alternative materialsGeneral cleaning

Press cleaning Storage/disposal

Parts washing

Best practice

PRODUCTOUTPUTS

CLEANINGMATERIAL

INPUTS

ENVIRONMENTAL

TECHNOLOGY

BEST PRACTICE

PROGRAMME

GG231GUIDE

COST-EFFECTIVE MANAGEMENT OF CLEANINGMATERIALS FOR PRINTERS

GOOD PRACTICE: Proven technology and techniques for profitable environmental improvement

© Crown copyright. First printed August 2000.

This material may be freely reproduced in its original form except for sale or advertising purposes.

Printed on paper containing a minimum of 75% post-consumer waste.

COST-EFFECTIVEMANAGEMENT OF CLEANINGMATERIALS FOR PRINTERS

This Good Practice Guide was produced by the

Environmental Technology Best Practice Programme

Prepared with assistance from:

Enviros Aspinwall

This Good Practice Guide provides printers in the sheet-fed and web-fed sectors with a frameworkfor generating cost savings, as well as operational and environmental benefits, through themanagement of cleaning materials.

Cleaning materials are often overlooked in press cleaning operations as a small cost when comparedto downtime due to cleaning. However, with a general rise in short-run print jobs, many printers arefinding that cleaning is becoming a major part of the working day and the volume of cleaningmaterials used is increasing. In addition, downtime costs, waste disposal costs and legal compliancecosts related to health, safety and the environment, make cleaning a significant financial issue.

The approach to cleaning materials management in this Guide is applicable to all sheet-fed andweb-fed printing processes. Using this Guide will help printers to:

■ understand the benefits of effective management of cleaning materials;

■ undertake a simple method of measuring the quantities of cleaning materials used andidentifying where material is wasted;

■ introduce practical methods for reducing cleaning material losses;

■ address the issue of using alternative cleaning materials to improve environmentalperformance whilst not impacting on operational efficiency;

■ implement actions that will generate cost savings and environmental benefits.

The Guide suggests many ideas that can be put into practice immediately. Other measures, such aschanging to alternative cleaning materials, require greater consideration. An Action Plan is includedto help you get started.

S U M M A R Y

Section Page

1 Why manage cleaning materials? 11.1 Cleaning materials cost money 11.2 Contain rising waste disposal costs 21.3 Cleaning materials are linked with environmental legislation 21.4 Health and safety issues 31.5 Managing cleaning materials can help to reduce downtime 4

2 Quantifying cleaning material use 52.1 Nominate a responsible person 52.2 Review the printing operation 52.3 Identify the locations for cleaning materials storage 62.4 Stock level measurement 62.5 Recording purchases 72.6 Recording health, safety and environmental impact 72.7 Recording potential environmental impact 82.8 Identify where cleaning materials are used 9

3 Making savings through improving cleaning material use 113.1 Opportunities for cost savings 113.2 Materials handling and storage 113.3 Reduction in use 123.4 Parts washers 133.5 Preventing solvent losses through evaporation 133.6 Solvent recovery 153.7 Automated washing systems 153.8 Press modifications 16

4 Alternative cleaning materials 174.1 Assessing the need for organic, solvent-based cleaning materials 174.2 Prioritise actions 184.3 Plan for change 194.4 Consider each cleaning application individually 194.5 Test alternatives 194.6 Example: Selecting an alternative blanket wash 20

5 Action Plan 23

Appendix Sample worksheets 24

C O N T E N T S

This Section outlines the reasons why printers should consider their use of cleaning materials inprinting operations. Section 2 will help you to log and review your current levels and patterns ofuse of cleaning materials. Section 3 will help you to reduce the cost of cleaning to your business -helping you to choose materials and methods that will save your company money on raw materialsand waste disposal charges. Section 4 will help you to take a longer-term view of your cleaningmaterials consumption and to identify where changes can be made to move to completely solvent-free cleaning products.

1.1 CLEANING MATERIALS COST MONEY

A major reason for managing cleaning materials is that they cost money - perhaps more thanexpected. By committing a small amount of time to investigating the cost of the cleaning materialsyou use, opportunities to reduce that cost will become evident.

The main parts that need cleaning are:

■ plate and blanket cylinders;

■ inking roller;

■ dampening roller;

■ press parts, eg grippers, sheet guides and impression cylinders.

Various washes are available and could be used for cleaning each of these parts. Also used forcleaning are rags and cloths.

Typical costs for printing cleaning materials used in lithography are presented in Table 1.

Table 1 Typical costs for printing cleaning materials used in lithography

Many printers consider that the cost of cleaning materials is small when compared to the downtimecosts of undertaking the press cleaning. Although the costs may appear small, they do add up.

For example, a sheet-fed printer wasting just 1 litre per shift of the typical cleaning materialsspecified in Table 1, could incur an annual financial loss of over £10 000 on a two-shift regime. Inaddition, downtime costs, waste disposal costs and legal compliance costs related to health, safetyand the environment, make cleaning a significant financial issue.

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W H Y M A N A G E C L E A N I N GM AT E R I A L S ?

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1

Type Application Typical price (£)

Manually applied, medium drying blanket wash Sheet-fed/web-fed 1.58/litre

Manually applied, ultra fast drying blanket wash Sheet-fed/web-fed 5.46/litre

Automatically applied blanket wash Sheet-fed/web-fed 2.52/litre

Plate cleaner Sheet-fed/web-fed 7 - 11/litre

Laundering soiled cleaning cloths All 55.56/1 000 cloths

1.2 CONTAIN RISING WASTE DISPOSAL COSTS

Cleaning produces a range of wastes including:

■ spent organic solvents;

■ inky wash-down effluents;

■ soiled cleaning cloths;

■ contaminated inks;

■ empty pots or containers.

In many cleaning materials the active cleaning ingredient is an organic solvent. The current chargefor disposing of 1 litre of organic solvent is around 40 pence, in addition to a collection charge.Reducing the amount of the solvent to be disposed of can bring cost savings that quickly add up.

1.3 CLEANING MATERIALS ARE LINKED WITH ENVIRONMENTALLEGISLATION

The organic solvent content of cleaning materials means that they have considerable environmental,health and safety impacts which also present a cost to your company in terms of regulatorycompliance. Printers are subject to a variety of increasingly stringent environmental legislation and,as a result, the cost of compliance is rising. Some of the main legislative issues are summarised below.

1.3.1 Waste disposal

The disposal of solvents, contaminated cloths, etc is covered by the Duty of Care regulations, whichrequire that all wastes are disposed of in a responsible manner, for example, by approved andregistered carriers and at fully licensed disposal sites. It also requires a company to inform the peoplehandling its waste of any potential hazards. Disposal costs are rising and so any measures thatreduce waste should provide cost savings. Waste cleaning products and organic solvent-contaminated rags are often classified as ‘special waste’, which attracts higher disposal costs.

1.3.2 Effluent disposal

Wastewaters disposed of via the trade effluent system often contain solvent-based materials. Anymeasures that decrease solvent use reduce the level of solvents in your trade effluent and can leadto cost savings.

1.3.3 Emissions to air

The use of organic solvent-based inks and organic cleaning agents leads to volatile organic solvent(VOC) emissions. Emissions to air from the printing industry in the UK are currently controlled bythe Local Air Pollution Control (LAPC) system introduced by the Environmental Protection Act 1990.

Companies that use specified amounts of organic solvents each year must register with theappropriate regulator (different regimes apply in England and Wales, Northern Ireland and Scotland- contact the Environment and Energy Helpline on 0800 585794 for more details). All organicsolvents, including cleaning organic solvents used by printers, contribute to the total emissions ofVOCs. The threshold for registration for most printers is 5 tonnes of organic solvent/year in England,Wales and Scotland. There is a different threshold for sheet-fed lithographic and cold offset printers.

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Cost saving idea:

Have you considered how much you actually spend on disposal of cleaningmaterial wastes? You can make a quick assessment by looking at invoices youhave paid to waste management contractors.

£

Printers producing large amounts of VOC emissions are required to adopt a VOC reduction strategy.Guidance on complying with the legislation can be found in the Secretary of State’s Guidance Notes,eg PG 6/16(97) Print Works and PG 6/17(97) Printing of Flexible Packaging1. These documentscontain a section that specifies certain requirements for on and off press cleaning. They also definelimits for the vapour pressure (a measure of solvent volatility) of certain commonly used cleaningmaterials, including blanket wash used in offset litho.

At a European level, the Solvents Directive (1999/13/EC) will have an impact on many industrysectors, including printing. The Directive will affect only printers that are already covered underLAPC but it will introduce more demanding emission limits, in particular, on uncontrolled releasesfrom processes (known as fugitive emissions).

The Pollution Prevention and Control Regulations 1999 are applicable to those printing companiesthat are currently regulated under LAPC and Integrated Pollution Control (IPC) as they operate a ‘PartB’ or other regulated process. These new regulations have been introduced in response to the ECIntegrated Pollution Prevention and Control (IPPC) Directive. The regulations bring in a new systemof control for Part B and other regulated processes that replaces the current system. For more specificguidance on these regulations contact the Environment and Energy Helpline on 0800 585794.

For information on how to measure the amount of organic solvent you use in your process, order acopy of Good Practice Guide (GG114) Reduce Costs by Tracking Solvents, available free of chargethrough the Environment and Energy Helpline on 0800 585794.

1.4 HEALTH AND SAFETY ISSUES

Many cleaning materials contain high concentrations of organic solvents which can cause harm tothe health of print workers and the environment. Due to the amount and nature of organic solventin cleaning materials, many products used are potentially hazardous to health.

As well as the health effects associated with some organic solvents, there is also the risk ofexplosion. Explosions can occur in the dryer and fires on presses are not uncommon. They occurwhen the build-up of organic solvent vapour forms an explosive mixture in the air. Fire andexplosion risks are due to the low ‘flash point’ of many organic solvents. Flash point is thetemperature at which a chemical will sustain a flame. As the flash point increases, so does the safetylevel. Your local fire authority can give you advice on general fire precautions.

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For further information on legislation affecting printers, call the Environment and Energy Helplineon 0800 585794 or, alternatively, look on the Environment Agency’s Netregs internet site athttp://www.netregs.environment-agency.gov.uk/mainmenu.html

1 Guidance Notes are available from The Stationery Office Publications Centre, PO Box 276, London SW8 5DT.Tel: 020 7873 0011. Fax: 020 7873 9090.

For more information contact the Health & Safety Executive Infoline on 0541 545500. A numberof useful publications are also available from HSE Books. For example:

■ The Printers’ Guide to Health and Safety, Printing Industry Advisory Committee (PIAC) forHSE, 1998, ISBN 0 7176 1486 7;

■ Chemical Safety in the Printing Industry, Printing Industry Advisory Committee (PIAC) forHSE, 1995, ISBN 0 7176 0846 8;

■ The Storage of Flammable Liquids in Containers, HSE, 1998, ISBN 0 7176 1471 9.

1.5 MANAGING CLEANING MATERIALS CAN HELP TO REDUCEDOWNTIME

Companies that follow best practice are aware that operating effective cleaning routines will reducethe incidence of non-productive downtime to an absolute minimum. As the hourly cost rate caneasily exceed £100, any reduction in downtime is desirable.

Management of cleaning materials can help to reduce the downtime associated with press andequipment cleaning by:

■ ensuring that the correct cleaning materials are used;

■ reducing waste of materials while cleaning is being undertaken;

■ ensuring that cleaning materials are easily to hand when cleaning is required.

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Cost saving idea:

Link compliance with environmental and health and safety legislation withgenerating cost savings and environmental benefits. For example, whenundertaking health and safety checks in the workplace also look foropportunities to reduce the use of cleaning materials.

£

This Section provides information on how to conduct a full review of cleaning materials used in anyprinting operation. With the information generated from undertaking a review it is easier to:

■ implement measures that reduce the use of cleaning materials;

■ target products for possible replacement with lower organic solvent or non-organic solventalternatives.

2.1 NOMINATE A RESPONSIBLE PERSON

Before starting to look at cleaning materials, nominate a responsible person to carry out the exerciseand to co-ordinate the findings. The responsibilities of the nominated person should include:

■ collecting and collating information on the materials used;

■ selecting priority action areas;

■ identifying waste prevention ideas (in conjunction with process operators);

■ setting up waste reduction teams;

■ raising awareness of waste reduction in the workplace;

■ initiating performance monitoring systems.

2.2 REVIEW THE PRINTING OPERATION

The starting point of the cleaning materials review is to study the overall printing operation. This isto determine the extent of the printing operation to allow you to plan the rest of the review.Information required at this stage is included in Table 2.

Table 2 Information needed for your review

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Q U A N T I F Y I N G C L E A N I N GM AT E R I A L U S E

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2Remember:

If you don’t measure it, you can’t manage it.

Criteria Information required Use of information

Printing business Number of sites to be considered, Helps to determine how much time you ie single site, multiple sites. will need to put into the review.

Process stages Number of process stages, ie pre-press, Helps to scope which areas in the businessplate-making, press etc. to look at.

Shifts and teams Organisation of departments or teams Use within each shift will be different andetc, ie number of staff and shifts. should be taken into account.

2.3 IDENTIFY THE LOCATIONS FOR CLEANING MATERIALSSTORAGE

On a floor plan or suitable map of the printing operation simply plot the locations of all:

■ Cleaning materials storage areas and containers. It is important to record all permanent‘fit-for-purpose’ storage containers and areas. In addition, it is vital to record all ad hoc andtemporary locations. For example, under benches or on top of the press.

■ Cleaning wastes disposal storage areas and containers. It is important to record allpermanent and temporary locations, as above.

Taking into account construction, suitability and health and safety, on a separate sheet record thecondition of each location. If you run a number of shifts you may find slight changes in the locationsof cleaning materials storage areas, as staff may have personal preferences.

2.4 STOCK LEVEL MEASUREMENT

Once the location of the chemicals and wastes stored have been identified, the next stage is toundertake stock level measurement. You will need suitable protective equipment for this exercise:gloves, goggles, mask and overalls. You should go to each storage location and note whatchemicals are stored inside. Areas that you will need to look at include:

■ stock rooms;

■ external chemical stores;

■ pre-press and pressroom cabinets and shelves;

■ pre-press machines, the press and other surfaces;

■ cleaners’ cupboards.

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Action point:

From the information collected on cleaning material storage areas it is possible to build up apicture of whether storage and disposal of chemicals are being undertaken in the most efficientway. For example, how far do staff cleaning the press have to walk in a shift to refill cleaningmaterial containers or dispose of a rag?

You will find that many of the ad hoc and temporary storage areas for cleaning materials areactually the optimum location. For example, storage areas may be moved during shifts toaccommodate ‘desire-lines’, ie the shortest distance from the container to the press.

The main cost saving from this exercise is time saving. By talking to staff you can determine themost efficient location for storage and disposal areas. You may have to move some locationsand upgrade temporary areas to be more permanent. Health and safety and storage capacity(see Section 2.4) will have to be taken into account.

Save a minute:

If optimising the location of storage and disposal areas saved only 1 minute in time per shift, aprinting company operating a daily two-shift regime would save an 8-hour day per year.

This is a useful exercise as you will find that many cleaning materials are out-of-date, are part of acompleted trial, are no longer used, have no label or are in need of safe and legal disposal. Oncethe stocktake is complete, consider a ‘spring-clean’.

Useful data to record include the type of cleaning material, the quantity stored and its location inthe building. For full containers, note down the quantity, and for part containers simply record anestimate of quantity. For those you don’t need, find a safe and legal disposal route - recording themfirst as ‘disposed of stock’.

Recording the types and quantities of cleaning materials you have stored in the business is a usefulexercise, some of the benefits include:

■ removing out-of-date or unknown cleaning materials;

■ making space;

■ recording stock levels of commonly used materials, thus avoiding over-ordering.

2.5 RECORDING PURCHASES

The next stage is to seek out information on the types and quantities of cleaning materials you buy.This information can be available from your accounts department where the supplier’s invoiceusually includes the quantities of materials purchased. You can either decide on a date to startmonthly recording or, if you have more time, establish trends from past years’ invoices. Once everysix months, stocktake again to determine patterns of cleaning materials use against purchases.

It is also useful to determine how much is actually paid for each material that is used. By knowingthe cost of each material, the costs of waste can be determined and the benefit of wasteminimisation calculated.

2.6 RECORDING HEALTH, SAFETY AND ENVIRONMENTALIMPACT

Simply knowing what cleaning materials you have stored and what you buy is valuable managementinformation. However, there is a range of other valuable data that can be collected at the same timethat will assist in future cleaning material purchasing strategies. This can be linked to purchasingalternative products described in Section 4. For example, during the review the following can berecorded:

■ environmental impacts of the products used;

■ health and safety aspects of the Control of Substances Hazardous to Health (COSHH)regulations.

Waste disposal costs can also be significant for some materials. It is practicable and saves time togather information on these issues during the cleaning materials review.

During the review of cleaning materials you will find that many products will have labels describingthe particular health and safety risks that arise from their use. In addition, some may also describethe potential environmental impact. Information concerning the above is detailed on the productitself or on the material safety data sheet. Sometimes you will need to go back to the supplier formore information. There is much health and safety related information that can be recorded at thisstage and it is recommended that you consider the COSHH regulations.

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2.7 RECORDING POTENTIAL ENVIRONMENTAL IMPACT

Not all cleaning materials contain the same level of solvents. Changing products to use thosecontaining a lower level of solvents is the first, simple step towards reducing your costs and reducingthe impact on the environment. Section 4 gives guidance on how to change to products thatcontain no solvent, which is a bigger step.

Many organic solvents have the desirable property of rapid evaporation whilst cleaning and aretermed volatile organic compounds (VOCs). However, when released into the atmosphere, theseVOCs are the subject of increasingly stringent environmental legislation. Reducing VOCs in theprinting operation also has significant health and safety benefits and the following list categorisessolvents, taking account of both health and safety and environmental requirements.

All cleaning materials can be categorised into three groups in terms of flammability:

A Highly Flammable (Flash-point <21°C)

B Flammable (Flash-point 21 – 55°C)

C Not flammable (Flash-point >55°C) (high boiling point hydrocarbons and vegetablecleaning agents).

Material safety data sheets provide information on the flammability of a product in the RegulatoryInformation Section.

Materials in Category A generally have the highest VOC content because they are the most volatile,and this reduces as you move to Category B and on to Category C as part of a VOC reductionstrategy. Therefore, increased use of cleaning materials with higher flash-points (ie a change fromA to B, or B to C) would reduce VOCs at source. To gain the most reduction, the longer-term aimshould be to work towards eliminating the use of those in Category A, and using higher percentagesof chemicals in Category B or, better still, Category C.

Completing Worksheet 1 as part of the cleaning materials review will highlight the percentage ofchemicals your company is using in each category. An example of a completed Worksheet 1 isshown in Fig 1. A blank worksheet that can be photcopied has been included in the Appendix.Following a review of the materials used and the introduction of waste reduction methods,Worksheet 1 can be updated and used to monitor performance.

The information required to complete Worksheet 1 should be available from:

■ the site COSHH register;

■ material safety data sheets;

■ purchase records;

■ stocktaking records;

■ the stores inventory;

■ cleaning material suppliers.

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* Select a time period over which to quantify the material use that suits your company’s operations, for example monthly,quarterly or annually.

Fig 1 Completed example of Worksheet 1 - identifying cleaning materials used

2.8 IDENTIFY WHERE CLEANING MATERIALS ARE USED

After determining the quantity of materials purchased, you need to determine where the cleaningmaterials are actually used within a given period. This will help you to identify where improvementscan be made. For each cleaning material your company uses, you need to estimate its use in eachcleaning process you operate and compare the amount used with either:

■ press or equipment manufacturer’s recommended quantities required for cleaning;

■ the quantity you have determined is the ‘optimum’ quantity required to carry out the cleaningoperation - perhaps by comparing best practice between machines or shifts.

Worksheet 2 provides a method of recording the quantity of cleaning materials used in differentprocesses, to determine if excess material is being used and the costs of the excess. In addition, theworksheet can be used to identify if a material is being used in the wrong place. An example ofWorksheet 2 is shown in Fig 2. A blank worksheet that can be photocopied is included in theAppendix.

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Category Flammability Product Quantity Unit cost Percentage(flash point) name purchased (£/litre) used by

(litres)* category (%)

A Highlyflammable

(<21°C)

B Flammable(21 –55°C)

C Not flammable(>55°C)

Total 5 850 100

White spirit 4 000 0.8

High wash 1 250 1.10

Clean wash 400 1.10

Vegetable ester 200 1.75

89.74

6.84

3.42

* Select a time period over which to quantify the material use that suits your company’s operations, for example, monthly,quarterly or annually.

† Enter the equipment manufacturer’s recommended quantities required for cleaning or a quantity you have determinedis the ‘optimum’ quantity required to carry out the cleaning operation.

Fig 2 Completed example of Worksheet 2 - quantifying cleaning material use

Depending on the size of your company and the number of jobs you run, quantities can becalculated:

■ for your company as a whole;

■ by press (useful when comparing material consumption of different presses);

■ by print job (useful for comparing material consumption on repeat print runs).

You may wish to calculate use at all levels or choose one option. The information produced shouldreveal the area where most cleaning materials are used and allow waste reduction activities to betargeted in these areas first. Worksheet 2 can be completed on a regular basis as a method ofmonitoring continuous improvement.

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Product name White spirit Unit cost (£/litre) = 0.80

Quantity Recommended/ Excess Cost of Reasonsused* optimum† quantity excess for Process(litres) quantity (litres) (litres) (£) excess

(A) (B) (A–B)

Plate and blanketcylinder washing 500 450 50 40 Not known

Inking rollerwashing – – – – –

Dampeningroller washing 10 8 2 1.60 Not known

General cleaningof press parts(grippers, sheetguides, impressioncylinders) – – – – –

Total use 510 458 52 41.60

3.1 OPPORTUNITIES FOR COST SAVINGS

There are several areas of good practice relating to cleaning materials operation:

■ materials handling and storage;

■ reducing the use of cleaning materials and increasing the efficiency of cleaning material use;

■ reducing losses of cleaning materials through evaporation;

■ recovery of cleaning materials;

■ modification of presses to reduce cleaning requirements;

■ replacing conventional cleaning materials with products that have lower environmental impacts.

The first four areas of good practice are good housekeeping and materials management that relateto the materials currently being used and are discussed below. The last two are longer term projectsand require careful consideration. They are discussed in detail in Sections 3.8 and 4.

3.2 MATERIALS HANDLING AND STORAGE

Good practice procedures can virtually eliminate wastes from spoilage and improper storage, andreduce waste from material handling. All areas where materials are handled and stored are worthyof review to see where opportunities exist for reducing waste.

A prime location for waste reduction is in the goods-in area, where the acceptance of unusable ordamaged materials, or incorrect ordering and stock rotation result in unnecessary wastes. Bylimiting purchasing authority to a nominated individual, a company may be able to gain greatercontrol over purchasing and limit incorrect ordering or acceptance of unsuitable goods.

To avoid accepting unwanted materials that will eventually have to be disposed of, a printer canadopt a policy of not accepting any material samples or trials without authorisation of thenominated individual. In addition, a printer could also provide an approved list of materials to thesupplier.

All materials should be inspected and the unacceptable materials returned immediately to themanufacturer or supplier. The savings here are two-fold - from avoiding having to purchasedamaged goods and pay for their subsequent disposal. Use a first-in, first-out inventory system,check expiry dates and heed storage specifications for materials to ensure goods on the shelf arewithin their shelf-life.

Proper storage of cleaning chemicals should, at a minimum, meet the label specifications and healthand safety requirements. By meeting the required conditions, the shelf-life of a chemical can beguaranteed and the likelihood of spoilage decreased. Proper storage will avoid damage fromtemperature, humidity and spills, as well as physical damage. It may also be necessary to restrictaccess to the storage area to avoid damage from dust, dirt and spills. All storage areas should beclearly labelled as to content.

When using solvent-based cleaners, especially when opened, they should be stored safely. Attentionmust be paid to flammability and flash-point.

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MAKING SAV INGS THROUGHIMPROVING CLEANING MATER IAL USE

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3.3 REDUCTION IN USE

3.3.1 Job planning

Thorough planning of the overall job load will reduce wastes. Planning allows for scheduling of thedaily runs to reduce colour changes and to run inks from lighter to darker. Both techniques reduceheavy cleaning steps.

3.3.2 Press cleaning

Care should be taken not to use more cleaning material (usually organic solvent), than is necessary- only the minimum needed to do the job should be used, as anything above this is just waste. Inorder to achieve a high quality print, printing equipment needs to be kept clean. If components arewashed infrequently, inks harden and more aggressive cleaning materials need to be used. It is alsovery easy to adopt a policy of excessive washing; it is, therefore, important to strike the right balance.

Consider re-using any solvent used for manual cleaning - remember, dirty solvent can still clean. There-use of cleaning solvents not only reduces pollution through effective use of resources andmaterials, but can reduce costs. Depending on the job, if solvents are needed to clean press parts,consider using recovered solvents. Any solvent tanks and containers should be kept closed toprevent evaporation and emissions, and full account should be taken of health and safety issues.

Changing from high VOC content cleaning materials to materials with low or no VOCs will reduceair emissions. Bear in mind that for short print runs, more VOCs are usually released fromevaporating press cleaners than from the inks themselves.

Several simple procedures can reduce the quantity of cleaning material solvent used for presscleaning and the associated VOC emissions.

■ Minimise the solvent applied to a cleaning wipe by using suitable plunger cans with a piston-type dispenser or squeeze bottles.

■ Use press wipes as long as possible before discarding. Use soiled wipes for the initial pass andclean ones for the last.

■ Store used solvent-contaminated rags in sealed, fireproof containers labelled ‘contaminatedrags’ to avoid solvent evaporation and a safety hazard.

■ Consider an automatic press-cleaning system, such as an automatic blanket wash for off-setlitho presses.

Increasing the use of higher boiling point solvents is discussed in Section 2.7. Even solvents with ahigh VOC content may evaporate at such a low rate that less solvent is used. Use of non-solventalternatives is discussed in Section 4.

During cleaning operations, equipment can be introduced that will reduce wipe and solvent use.The least technical of these is the employment of squeegees to remove excess liquids fromequipment. This, in turn, will reduce the quantity of wipes required. An automated cleaning systemcan further reduce residual liquids and, in turn, reduce consumption of cleaner. An example of thissystem is an automated blanket cleaner. The choice of equipment is dependent on the type ofprinting operation. Any new equipment will require training of plant personnel as well as their co-operation in changing their working practices.

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3.3.3 Improving cleaning on litho presses

The first step in improving the efficiency of litho press cleaning is to conduct a review of cleaningoperations and to make sure press components are cleaned only as and when required. Thefollowing are some suggestions for improvements:

■ Review when press components and blankets are cleaned to determine if a reduced cleaningfrequency will still keep the equipment clean. Print quality will need to be monitored toensure it is not affected by less frequent washing.

■ Try to select the running order of print jobs based on the colour of the ink, starting with lightcolours and moving to dark. This can reduce the amount of cleaning materials needed overa shift or week.

■ The overnight drying of inks in ink ducts can be prevented by spraying them with ‘anti-skin’aerosols. This reduces both the volume of ink wasted and the volume of cleaning materialrequired to get the press operational for the next shift.

3.4 PARTS WASHERS

There is often a need to clean or soak press parts within the printing operation. In most cases smallparts are cleaned, but for some web presses large parts may need to be soaked. Common poorpractice is to use any empty container such as an empty ink tin filled with solvent. This usuallyresults in high levels of solvent evaporation, with its associated impacts on costs, health and safety,and the environment.

It is worthwhile reviewing the current method employed to soak press parts. It is recommended thatpurpose-built parts washers which meet health and safety requirements are introduced. Partswashers should be used with high boiling or flash-point solvents to reduce the risk of explosion.Installing a filtering mechanism in the parts washer will extend the life of the solvent.

3.5 PREVENTING SOLVENT LOSSES THROUGH EVAPORATION

Many cleaning materials contain high concentrations of volatile substances that evaporate rapidly givingthese materials their quick drying effects. Losses through evaporation should be minimised because:

■ the evaporated materials are wasted and could have been used for cleaning, which wouldresult in better utilisation of the materials purchased;

■ they result in adverse environmental and health effects;

■ organic solvent vapours can pose a fire or explosion hazard.

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Industry Example 1 - Changing the press clean-up procedure

A gravure printing company has reduced cleaning solvent use and saved time through theintroduction of a new press cleaning procedure.

Under the old cleaning procedure, ink trays and doctor blades were ‘cleaned down’ betweenproduction runs with cleaning solvent. The solvent was recovered for re-use in future ink batches.At the suggestion of an employee, the company has introduced a new cleaning procedure thathas eliminated a cleaning stage. The employee noticed that the ink residue remaining on thedoctor blades and the cylinder contained sufficient solvent to allow cleaning with dry rags alone.No additional cleaning solvent was necessary. By adopting the use of dry rags, the companyeliminated around 60 solvent-laden rags per day. Downtime has also been reduced from 90minutes per clean-down to 10 - 20 minutes, saving around 2 300 labour hours/year.

Simple measures to reduce losses through evaporation include:

■ Keep storage containers closed.

■ Use dosage pumps or release valves to dispense materials.

■ Use small containers on the shop floor, such as fine spray wash bottles or plunge cans thatapply only a specific amount of blanket wash during manual washing operations.

■ Use a smaller cloth as this reduces both the amount of cloth needing recovery or disposal andthe quantity of blanket wash needed to dampen the cloth.

■ Minimise the volume of wash applied to rags and ensure that excessive amounts are not used.

■ Keep spent rags in sealed containers.

■ In addition to the above listed issues, it is important that working areas are properlyventilated, using extraction systems if required. Storage facilities should be properly designedto take account of the type of container.

■ Large drums should be stored in a secure outdoor area, protected from direct sunlight andfrom vandals.

■ Flammable materials stored indoors should be kept in a fire-resistant store.

3.5.1 Managing cleaning rags and wipes

Cloth cleaning wipes covered in ink and solvent can be re-used by sending them to an industriallaundry service. It is advisable to remove the majority of liquids by a gravity drain, a wringer or acentrifugal extractor prior to shipping. Use caution in doing this, as solvents used may be flammable.The extractor should be explosion proof and follow health and safety guidelines2. This recoveredsolvent can be used initially for parts washing, recaptured, then distilled for re-use or sent out foruse as fuel. The used wipes should be stored in an air-tight, self-closing, flame-resistant containermarked for recycling and laundry. For those printers that cannot remove the solvent themselves fromcleaning rags, some waste management contractors can collect rags for solvent recovery prior tolaundry (see also Section 3.6).

Used cleaning cloths, wipes and rags will contain a small volume of flammable cleaning materials.However, many printers also pour additional spent cleaning solvents into the spent cloths container.In particular, solvents from the roller wash tray are often poured into this container. This is badpractice that should be stopped because it poses unacceptable health and safety hazards. Allorganic solvents not actually in cloths should be poured into a suitable container for appropriatedisposal. The fire risks associated with the evaporation of cleaning solvents are highlighted by anincident identified by the Health and Safety Commission.

14

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3

Industry Example 2 - Fire risk associated with evaporation of cleaning solvent

Press wipes from a printer using flammable solvents were received at a commercial laundry. A largebag of wipes was tipped onto the laundry floor and left, allowing time for solvent held on the wipesto evaporate and form a flammable atmosphere in the work room. An explosion followed, whichled to an extensive fire causing damage to the building and to plant and equipment. Fortunately,nobody was in the room at the time of the explosion and there were no injuries.

2 The Printers’ Guide to Health and Safety, Printing Industry Advisory Committee (PIAC) for HSE, 1998, ISBN 0 7176 1486 7and The Storage of Flammable Liquids in Containers, HSE, 1998, ISBN 0 7176 1471 9.

3.6 SOLVENT RECOVERY

Steps to minimise the amount of solvent used for cleaning should be taken first, before solventrecovery options are considered. Manual washing operations result in solvent soaked cloths andrags. The solvent which remains on these rags can be recovered, either on-site or off-site, providedthey are stored to prevent VOC loss.

On-site recovery is an option that may be available to larger printers. In the USA, a number of printershave invested in a centrifuge system that recovers excess solvent, which is then re-used for cleaningoperations. Such systems should pay for themselves within a year. For some printers, an on-sitesolvent distillation unit can be a viable option if large quantities of cleaning solvent are used.

On-site recovery is unlikely to be a viable option for smaller printers. However, waste managementcontractors do collect rags for solvent recovery prior to laundry. Prior to agreeing contracts withwaste management companies, find out what they do with the rags and whether they carry out anyrecovery or recycling processes. It is a legal requirement under the Duty of Care regulations to beaware of how and where your wastes are disposed of.

3.7 AUTOMATED WASHING SYSTEMS

Installing automatic washing equipment on lithographic presses can increase press efficiency andimprove safety. The options available are discussed below.

3.7.1 Blanket cylinder auto washers

These are available for both web and high specification sheet-fed presses. They incorporate eithera wiper or a brush cleaning mechanism. The advantage of this system is that the litho press can becleaned during a press run rather than stopping the press and using manual cleaning methods. Thiscan save time, wasted substrate and cleaning materials.

3.7.2 Transfer/impression cylinder auto washers

Less common and generally available for sheet-fed only, these clean the impression cylinder that canpick up debris etc from the substrate.

3.7.3 Inking roller semi-auto washers

This washer can only be described as semi-automatic as much of the work is undertaken manually.The washer comprises a wash-up tray that is screwed into position in a specific location under theinking rollers. Solvents are sprayed onto the rollers which are turned slowly, releasing inky residueinto the inking roller wash-up tray.

When used correctly automatic washing systems can reduce the quantity of cleaning materials usedand also save time and, potentially, substrate. They should be maintained on a regular basis for thebest results to be achieved from them.

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3

Advice on cost-effective solvent capture and recovery is given in two Good Practice Guidesavailable free of charge through the Environment and Energy Helpline on 0800 585794:

■ (GG12) Solvent Capture for Recovery and Re-use from Solvent-laden Gas Streams;

■ (GG100) Solvent Capture and Recovery in Practice: Industry Examples.

3.8 PRESS MODIFICATIONS

Discuss with your press manufacturer if there are any procedures or modifications that will reducepress-cleaning time while maintaining the effectiveness of the cleaning operation. Recentdevelopments that can contribute to reducing cleaning time and ink waste are discussed below.

3.8.1 Automatic ink dispensing systems

Ink is pumped directly to the press ink ducts, removing the need for manual filling of the ink ductsby container. This avoids the cleaning of ancillary equipment such as buckets and can reduce spillageand clean-up.

3.8.2 Ink cartridge dispensing systems (for sheet-fed litho presses)

Ink is supplied in cardboard or plastic cartridges. This can remove the need for cleaning of ancillaryequipment such as containers and can reduce spillage and clean-up.

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This Section introduces some of the alternative cleaning products available and will help printers tointroduce some of them to replace solvent-based products. Today, printers are faced withincreasingly stringent legislation, designed to reduce the use of these solvents in order to protect theenvironment and the health and safety of those working in the industry. To overcome the negativeaspects of organic solvents, less harmful cleaning products are being developed all the time andmany effective alternatives are available. Vegetable oil-based cleaning agents virtually eliminateinhalation hazards, thus the effects on health and the environment are reduced to a minimum. Eveninsurance premiums can be reduced if less solvent is stored due to a lower fire risk on premises.

These alternative materials do not increase the work effort associated with cleaning. However, it isthe changeover that can, in practice, produce problems. These can be overcome by careful planningand effort, particularly in the transition phase.

4.1 ASSESSING THE NEED FOR ORGANIC, SOLVENT-BASEDCLEANING MATERIALS

Many printers use organic, solvent-based cleaning materials for all cleaning operations irrespectiveof whether or not these properties are required.

Using this Guide, printing companies aiming to reduce the amount of high solvent contentchemicals will be working towards higher percentages of chemicals in Category B or Category C (asexplained in Section 2.7). The ultimate long-term aim for printers wishing to improve theirenvironmental credentials and save themselves money is to replace organic solvent-based productswith non-solvent-based detergents, although, in practice, it will mean starting with just one or twoapplications.

Substitution of alternative products is best achieved step-by-step. By following Sections 2 and 3 ofthis Guide you will already have started to be more aware of the products you are using and shouldbe using less solvent overall. A recommended first step is to try to eliminate those cleaning materialsthat contain organic solvent with very low flash-points (ie below 21°C). This will provide significanthealth, safety and environmental benefits to your operation. This can be achieved by:

■ reviewing the processes for which the cleaning products are used;

■ determining, for each identified cleaning process, whether a high organic solvent content andrapid drying are an absolute requirement, or whether alternative cleaning materials or evennormal detergents would suffice.

A good principle to follow is to aim to use an increasing percentage of cleaning materials with highflash-points or to eliminate volatile organic solvent cleaners completely. By going in stages you willfind it much easier to adapt your operation to the new cleaning properties. Use the guide in Fig 3when assessing all of the cleaning materials you use. Aim to eliminate organic solvent cleaners (butdon’t just replace with a hazardous alternative!). Aim to eliminate cleaning stages whenevertechnically feasible.

In the same way that you will have identified which cleaning processes can be satisfactorily carriedout with higher boiling point products, so there may be some areas where non-solvent cleaningproducts could be used. However, these products often clean in a different way, therefore, somechange in working practices will be required.

17

A LT E R N AT I V E C L E A N I N GM AT E R I A L S

4

section

4

Fig 3 Guide to assessing cleaning materials

Your supplier will be able to help you to identify the best products on the market for your needs,but the best way forward is to trial each product in your own particular situation before acceptingit as a substitute.

In some cases the type of cleaning material used on a press is part of the warranty - check with yourpress supplier before making any change.

4.2 PRIORITISE ACTIONS

A typical sheet-fed or web-fed printing company will be using a number of different cleaningproducts for different applications. When deciding to investigate alternative cleaning materials it isimportant to prioritise activity to gain the best advantage. The first stage is to decide the mainobjectives of seeking alternative cleaning products, these can include the need to reduce:

■ VOC emissions;

■ costs;

■ health, safety and environmental impacts;

■ cleaning inefficiency.

In many cases a combination of all factors is desired. For some alternative cleaning products all ofthe above objectives can be achieved, in other cases one or two factors will be achieved and acompromise will have to be made on others.

There are many cleaning products and brands available to the UK printing industry. New solvent-free alternatives for cleaning are continually entering the marketplace. For more information contactthe Environment and Energy Helpline free of charge on 0800 585794.

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Flashpoint Target

100°C+ Aim to reach this level for at least some of the materials you use.

55°C+ Look to use this on all new presses as standard. Check withthe press supplier on what cleaning material is recommended.

21 - 55°C Look to use this type only on existing presses where fortechnical or contractual reasons there is no possible alternative.

Less than 21°C Aim to eliminate this type of cleaning material by changing toone with a higher flash-point.

For what processes are low organic solvent or non-organic solvent washes suitable ordesirable?

■ Slower working solvents are suitable for routine cleaning of metal parts of the press.

■ In order to clean a chain of ink rollers, a solvent that is slow to evaporate is desirable. If thewash evaporates before having passed through the chain, it will not clean it adequately.

Always look to eliminate cleaning wherever possible by addressing technical barriers.

4.3 PLAN FOR CHANGE

When undertaking any change it is important to research the area carefully before deciding on thebest course of action. The important issues to consider when deciding on alternative cleaningproducts are outlined below.

■ Will cleaning time be increased resulting in longer press downtime?

■ How will quality be affected?

■ What chemicals are used in the cleaning material?

■ What legislation might be avoided or triggered by the adoption of alternative products?

■ What health risks are associated with the new material?

■ Are there any different safety issues associated with the new material?

■ What are the environmental impacts of the product, including impacts to aquatic life?

■ Are there any waste disposal issues associated with the alternative material?

Suppliers should be able to answer all of the above questions. Where possible, shop around toobtain information on as many products as possible.

4.4 CONSIDER EACH CLEANING APPLICATION INDIVIDUALLY

It is important to understand the impact on the whole printing operation of changing each cleaningmaterial. Some cleaning materials are used only for a specific purpose, whereas other generalpurpose cleaners are used for a wide range of tasks. Make sure that you understand the impactthat changing a particular cleaner will have on all these tasks.

4.5 TEST ALTERNATIVES

Many suppliers are keen to encourage printers to trial new products. Where switching to analternative product will mean large-scale changes, it is worthwhile to set your own criteria beforeundertaking small-scale trials to see if they work in practice.

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The Environmental Technology Best Practice Programme has published Guides on other aspects ofchemicals management that may also help in your waste minimisation programme. They are allavailable free of charge through the Environment and Energy Helpline on freephone 0800 585794.

For guidance on the management of VOCs and cleaning materials in printing operations see:

■ (GG13) Cost-effective Solvent Management;

■ (GG28) Good Housekeeping Measures for Solvents;

■ (GG114) Reduce Costs by Tracking Solvents;

■ (GG230) Cost-effective Chemicals Management for Printers.

Other useful Guides for printers include:

■ (GG163) Cost-effective Ink Management for Printers, which deals with estimating theamount and value of ink losses and measures to reduce ink related waste etc;

■ (GG107) Cost-effective Substrate Management for Printers;

■ (GG143) Practical Measures to Save Money in Screen Cleaning and Reclamation.

4.6 EXAMPLE: SELECTING AN ALTERNATIVE BLANKET WASH

Set out below is a systematic approach to selecting an alternative blanket wash. The process can befollowed for any alternative product. It provides a structure for the process and will help to highlightthe issues that need to be considered when undertaking a replacement project.

4.6.1 Research alternative products

Start by gathering as much information as you can. Visit trade exhibitions, talk to suppliers and usethe internet to research various alternatives to organic solvent-based blanket washes. There are arange of alternatives, including:

■ water miscible solvents that are diluted with water, resulting in a lower VOC content;

■ vegetable oil-based cleaners have a low VOC content (12 - 30% undiluted or 2% inester/water mixtures) and have a lower flammability; as a result of which they do not havespecial storage requirements;

■ terpene-based cleaners based on solvents derived from wood and citrus products.

Further research will help you to identify any barriers to be overcome, eg:

■ press suppliers usually specify which blanket washes should be used on their machines;

■ deviation from recommended products can result in warranties being invalidated;

■ recalibration of machinery may be required which can result in significant periods of downtime.

Commonly raised issues from the operators when trialling the new products are:

■ Longer drying times. This can be overcome by removing the cleaning material from theblanket with a clean wipe.

■ Thickness of substitute. Some of the substitute blanket washes are thicker and oilier thanorganic solvent-based washes. To deal with this difference, the wash should be given enoughtime to soak into the wipe by storing wipes in a sealed container with wash. Prior to usingthe wipes they should be wrung out above the container to remove excess wash.

■ Do the washes work on ink rollers? Suppliers can advise on the best techniques to apply thealternative materials to different press components.

■ Strong odours. Some citrus-based products may have a strong or unusual smell. Minimisethe volume of material used and, as with organic solvent-based washes, keep containersclosed to minimise this impact.

A suggested procedure to follow to identify a suitable alternative blanket wash is shown in Fig 4.

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Fig 4 Selecting an alternative blanket wash

21

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4

Contact press manufacturer,obtain information on

approved/recommendedblanket washes

Contact suppliers of cleanersto discuss alternative

blanket washes

Trial of new wash based onmanufacturer’s application

recommendations

Check wash for:■ Performance issues■ Health & safety issues■ Legislation issues■ Environmental issues■ Disposal issues■ Insurance issues■ Flash-point

Selectalternative

wash

Problemsresolved

Obtain additionalinformation

required

Wash does notmeet requirements

Discuss problems withsupplier/other printers

Performance ofwash is unacceptable -discuss with supplier/

other printers

Is the performance acceptablein terms of effectiveness,

quality and cleaning time?

YESNO

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Productworks

effectively

Review reasonsfor failure

4.6.2 Finding an alternative blanket wash for your needs

There is a vast array of alternative cleaning products available. It is important that the productsselected meet the requirements of the task in hand. Speaking to different suppliers andmanufacturers will help to identify the most suitable products.

To find out which blanket washes are approved for use, contact press manufacturers as well as pressdistributors. The main manufacturers draw up blanket wash specifications for each new model thatthe cleaning material manufacturers can use. Washes manufactured to these specifications areapproved for use on certain presses within the warranty conditions. Investigation of thesealternative products identifies that these products generate less VOC emissions and thus can reducethe cost of compliance with environmental legislation.

On a volume-by-volume basis, alternative blanket washes tend to be more expensive thanconventional washes at present. However, considerably reduced amounts are usually required,reducing the cost overall. Further cost savings will result from reduced waste disposal costs,environmental compliance costs and insurance costs. Lower evaporation rates result in reducedwaste and decrease the volume of cleaner purchased and used.

Getting used to new materials may take time. Follow suppliers’ instructions and consult with thesuppliers and other printers to see what works best. Once you have adapted to the use of newmaterials it will result in a safer, healthier workplace and a better environment. The range ofproducts available is continually changing, and their high rate of uptake in other countries is a clearindicator that they do meet the performance requirements of the modern day printing industry.

4.6.3 Buying new equipment

Some press suppliers specify a particular blanket wash to be used on their machines during the firstfew months of operation. Use of alternative blanket washes during this period can invalidate thewarranty. The reason for the specification of blanket wash is that the pores on the rollers closeduring the first few months, making them impermeable. If aggressive washes are used during thefirst few critical months, the rollers may be damaged.

After the first six months, a wider range of washes are more often available to printers. You mayneed to contact your press manufacturers for lists of approved alternative washes. Washmanufacturers will have information about the environmental impacts of the products.

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When choosing new machinery it is worth considering the time and effortinvolved in the cleaning cycle and choosing a machine that requires

cleaning solvents with a flash-point of 55°C or more to be used.

Now you have read this Guide, the next step in the process of improving themanagement of the cleaning materials you use is to draw up an Action Plan. TheAction Plan should include the following steps:

Identify a cleaning materials co-ordinator.

Review storage and disposal locations for cleaning materials.

Identify the cleaning materials used, using Worksheet 1.

Quantify where cleaning materials are used, using Worksheet 2.

Identify any methods of improving cleaning material use, focusing on goodhousekeeping and low cost measures first (using appropriate options fromSection 3).

Review the types of cleaning materials used and identify alternativematerials, using the guidance in Section 4, with the aim of moving awayfrom Category A materials (highly flammable <21°C).

Monitor your performance and review progress regularly, using theWorksheets as the basis of your monitoring.

Record improved performance including cost savings, environmentalbenefits and reduced consumption of materials.

Maintain regular discussions with employees. Disseminate details aboutbest practice.

If necessary, obtain help.

The Environment and Energy Helpline (0800 585794) can, freeof charge:

Send you copies of relevant Environmental Technology Best PracticeProgramme publications.

Tell you about relevant environmental and other regulations that couldaffect your operations.

Arrange for a specialist to contact your company if you employ fewer than250 people, at the discretion of the Helpline Manager.

23

A C T I O N P L A N5

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5

The following blank forms are intended for you to photocopy and use in your own company.

Worksheet 1 (Fig A1) can be used to assess the types of cleaning materials used, with the aim ofmoving away from Category A materials to Category C materials. (Fig 1 in Section 2.7 shows anexample of a completed worksheet.)

Worksheet 2 (Fig A2) can be used to determine the excess quantity of cleaning materials used andthe cost of using the extra materials. (Fig 2 in Section 2.8 shows an example of a completedworksheet.)

Following the introduction of waste reduction methods or alternative materials, the worksheets canbe used to monitor performance.

24

appx

A1

S A M P L E W O R K S H E E T SAppendix

Fig A1 Worksheet 1 - identifying cleaning materials used

* Select a time period over which to quantify the material use that suits your company’s operations, for example, monthly,quarterly or annually.

25

appx

A1

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(litres)* category (%)

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(<21°C)

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The Environmental Technology Best Practice Programme is a Government programme managed by

AEA Technology plc.

The Programme offers free advice and information for UK businesses and promotes

environmental practices that:

■ increase profits for UK industry and commerce;

■ reduce waste and pollution at source.

To find out more about the Programme please call the Environment and Energy Helpline on

freephone 0800 585794. As well as giving information about the Programme, the Helpline has

access to a wide range of environmental information. It offers free advice to UK businesses on

technical matters, environmental legislation, conferences and promotional seminars. For smaller

companies, a free counselling service may be offered at the discretion of the Helpline Manager.

FOR FURTHER INFORMATION, PLEASE CONTACT THE ENVIRONMENT AND ENERGY HELPLINE

0800 585794world wide web: http://www.etbpp.gov.uke-mail address: etbppenvhelp@aeat.co.uk