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Summer 2006

Articles

Combining Technology with Spray Application
By Lea Schellhorn
Iowa Waste Reduction Center

For years, the United States military has been using flight simulation technology to train their pilots. As the pilots train in this manner, variables are replicated that instruct the pilot in how to handle emergency situations as well as to provide training for them to reach their full potential. Completing this simulation training allows the pilots to gain experience and confidently handle multiple situations.

Now, spray paint technicians can reach their full potential in the same manner with the Iowa Waste Reduction Center's (IWRC) development of the VirtualPaint™ training system. Without ever using a drop of paint or generating an ounce of hazardous waste, spray technicians can develop and refine their spray painting skills.

When triggered, an instrumented spray gun with specialized software produces a realistic spray pattern which is then projected onto an interactive display. Real-life situations and equipment can be used in training to simulate the application of coatings and also to provide instruction on the proper methods to set-up the equipment in order to efficiently complete the application process. This allows the spray technician to train using coatings and spray guns they may face on the job. They are also able to make spray gun adjustments and set personalized target mil build to match the paint actually used in their day to day operations.

Once the spray technician has finished the virtual application, the spray technique and spray sequence can be analyzed to increase efficiency, decrease the amount of waste generated and ensure the most effective techniques are being utilized by viewing the "accumulation mode." The accumulation mode displays various color intensities of blue, green, red and black; each intensity representing a different film thickness. This in turn allows the technician to see the areas they are spraying too heavily or not heavily enough.

Using the VirtualPaint™training system eliminates the requirements of dedicating a paint booth, compressed air and safety equipment to training spray technicians. It also decreases operational hazards and eliminates volatile organic compound emissions and hazardous waste generation. As an added bonus, costs associated with training are greatly reduced and no clean-up is required!

For more information about the VirtualPaintâ„¢ training system, contact the IWRC at (319) 273-8905 or visit www.virtualpaint.us. The Iowa Waste Reduction Center (IWRC) is a service of the University of Northern Iowa.

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Soy-based Lubricants: A Machinist's Dream
By Joni Lindauer
Iowa Waste Reduction Center

Traditional metal working fluids are safely used by hundreds of thousands of workers, yet problems can still develop when petroleum fluids are used or when fluids are not properly managed or maintained. When this is the case, metal working fluids have the potential to cause adverse health effects through skin contact with materials and through inhalation from breathing fluid mist or spray. Major health concerns include skin irritation, allergic contact dermatitis, irritation of the eyes, nose and throat, and occasionally, breathing difficulties such as bronchitis and asthma.

In response to these adverse health effects, the New Environmental Technologies for Small Business (NETSB) program at the Iowa Waste Reduction Center (IWRC) has partnered with Environmental Lubricants Manufacturing, Inc. (ELM). ELM and the Agriculture-Based Industrial Lubricants (ABIL) research program at the University of Northern Iowa, to research the benefits and utility of soy-based metal working fluids. In their study with Iowa machine shops, it was found that, in most cases ELM’s manufactured soy-lubricant (formulated with the best-optimized USA-grown natural seed oils and select additives) surpassed the lubricity and performance of petroleum metal working fluids.

ELM currently produces SoyEasy Cool™ XXL, a semi-synthetic bio-stable, water-soluble metal working fluid concentrate, as well as other soy-based products. Designed to mix with water, SoyEasy Cool™ XXL forms a stable water-soluble emulsion that provides excellent cooling, lubricity and rust protection for use in a wide variety of grinding and machining operations. This bio-tech based fluid works great for general purpose cutting and grinding; milling tapping and reaming; gear cutting including: hobbing, gun drilling, broaching and shaping; sharpening high-speed steel and carbide cutting tools; and is excellent for use with ferrous material and aluminum.

Perhaps the most beneficial characteristic of such ag-based fluids is their ability to decrease the health hazards previously mentioned and create a safer, healthier work environment. SoyEasy Cool™ XXL does not contain toxic chlorine or sulfur. Due to its larger cellular composition, it also decreases the amount of mist generated when used. Because of the elimination of toxic chemicals and its vegetable oil base, the occurrence of dermatitis is significantly reduced. Other benefits (besides health) include the reduction of grinding wheel usage, the extension of tool life and improved centricity, accuracy and part run-out. Finally, because it is made from renewable USA-grown crop-based vegetable oils, this fluid can be treated as any other fluid when it comes time for disposal.

Since 1988, the Iowa Waste Reduction Center, a service of the University of Northern Iowa, has strived to meet the needs of Iowa’s small businesses in regards to environmental regulations and waste reduction. For additional information regarding the use of soy-based metal working lubricants or on any other environmental issue, please contact Sue Schauls at 319-273-8905. All services provided by the IWRC are free and remain confidential.

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On-Site Reviews Help Ensure Environmental Compliance
By Joni Lindauer
Iowa Waste Reduction Center

When it comes to environmental concerns, many small businesses don’t know where to begin. With ever-changing rules and regulations, keeping up with the proper procedures can be difficult. Maintaining environmental compliance is a common concern faced by nearly every business, large and small, no matter where they are located.

The Iowa Waste Reduction Center's On-Site Review (OSR) service provides free and confidential environmental assistance to small companies in Iowa. Since its inception in 1988, the IWRC has conducted over 2,750 on-site reviews at diverse business types in all 99 Iowa counties; more than any other program in the nation.

Small businesses (clients) that request in-depth assistance from the IWRC receive an on-site visit from one of the IWRC's waste reduction specialists. During the visit, the IWRC staff member tours the facility and learns about the company's operations and current waste management practices. Once the visit is complete, the staff member prepares a report within four weeks, reviewing relevant regulations and identifying pollution prevention opportunities. The report is confidential and provided only to the business who sought assistance. Shortly thereafter, the client receives an evaluation form to rate the IWRC service, and six months later, receives a follow-up phone call asking about the implementation of IWRC's recommendations and if any additional assistance is desired.

The IWRC's OSR service is a terrific opportunity for small businesses with less than 200 employees. IWRC can supply each business with the necessary information applicable to them in order to obtain and maintain regulatory compliance, avoid penalties and fines, reduce waste and possibly time and money.

Helping small businesses continue to adapt to changing rules and regulations and remain competitive in today's market is the goal of the OSR program at the IWRC. With the assistance services made available, Iowa businesses are able to establish solid roots that will serve as a foundation to feed their own success and contribute to a healthy environment.

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Mercury Thermostat Recycling
By Joni Lindauer
Iowa Waste Reduction Center

As time and technology change, so do appliances within a house or place of business. When new technologies and processes are developed, many tools associated with them become obsolete. Mercury thermostats are no exception. Whether a current mercury thermostat is no longer being used or is being replaced due to renovations or malfunction, when it comes time for disposal consider the option of recycling through the Thermostat Recycling Corporation.

Established by Honeywell, White-Rodgers and General Electric, the Thermostat Recycling Corporation (TRC) is a not-for-profit corporation that operates the thermostat recycling program. The TRC works with heating and cooling contractors and their supply houses, placing recycling containers at participating sites. Contractors then collect out-of-service mercury thermostats through their normal business practices and either provides them to a supplier or another contractor who participates in the program OR implements the program themselves. The thermostats are stored in collection boxes. When full, the collection boxes are sent to the TRC where the recycling process takes place. During recycling, the mercury switches are removed from the thermostats and then sent to another company that removes and purifies the mercury for reuse.

A list of heating, ventilation and air conditioning (HVAC) wholesalers that participate in the TRC program can be found at the National Electrical Manufacturers Association Website: http://www.nema.org/gov/ehs/trc/. Copy the link into your web browser and scroll down the page to open the TRC Wholesaler List. This list provides contact information for participating TRC facilities throughout the state.

Contractors and supply houses who choose to implement this program are asked to pay a one-time fee of $15 for each collection box they wish to use. The shipping costs from the wholesaler to the TRC facility are paid for by the TRC. When a full collection container is sent from a wholesaler, a replacement container will be sent out from the TRC with no additional fee. The only paperwork involved is that of the wholesaler placing an Authorized Return Service (ARS) label on the collection container so that the carrier will take the full collection container to the TRC. There are no specific requirements in regards to record keeping, however it is suggested to maintain a file of all ARS tracking numbers for reference.

Thermostats that are not currently being recycled may need to be managed as a hazardous waste because of the toxic threat that mercury poses to the environment and human health. If not properly managed, mercury has the capacity to impose many health risks on the environment (damaging effects on water quality, raising levels of mercury in fish and soil, etc.) as well as humans (headaches, emotional changes and respiratory effects). It is for this reason that mercury needs to be recycled.

The TRC program will accept most brands of residential wall-mounted mercury thermostats. However, this program is for wall-mounted mercury switch thermostats ONLY. Contractors should NOT accept loose mercury bulbs, liquid mercury or thermostats that are leaking mercury. It is important to return the entire thermostat because it provides protection for the mercury bulb during shipment. For proper disposal of the loose bulbs, liquid mercury and leaking thermostats, a local waste management authority should be contacted. Other items that will not be accepted are batteries, fluorescent lights and any other controls containing mercury.

The HVAC industry would like to see all out-of-service residential wall-mounted thermostats recycled, and encourages all participating sites to collect thermostats from individual homeowners as well as clients.

The TRC program is an entirely separate program from any warranty the thermostat may be under. There will be no change to any manufacturer's warranty program. Thermostats that are still under warranty should not be included in the recycling containers. Warranty credit will not be received if this happens. For best results, it is suggested that each manufacturer's current warranty policy be followed.

For further information on this recycling program, contact the TRC directly at 800-238-8192. As always, site-specific information and additional explanations for this waste reduction tool are available. Please call the Iowa Waste Reduction Center at 800-422-3109, or visit our website www.iwrc.org to set up an on-site review or to request information about any of the IWRC programs. All services of the IWRC are free and confidential.

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Iowa Waste Exchange News

IWE Partnership Yields Positive Results
By Shelly Codner
IWE Resource Specialist

On February 6, 2006, an early morning fire south of Marble Rock in Floyd County caused the loss of nearly 1,500 hogs (feeder pigs and sows). The hogs, housed in eight confinement buildings, were owned by Gary Rottler of Rottler Farms, Inc. Much of the building site was also destroyed. Rottler immediately contacted the Iowa Department of Natural Resources (IDNR) and Shelly Codner, Director of the Butler County Solid Waste Commission and Area C Resource Specialist for the Iowa Waste Exchange (IWE). In order to reduce the potential for groundwater contamination caused by burying the carcasses and to eliminate the need to landfill the fatalities, IDNR representatives recommended Rottler consider the idea of composting the lost hogs. Upon this recommendation, Codner contacted Bill Rowland of the Landfill of North Iowa to inquire about the availability of wood chips and mulch to be used in the establishment of the compost pile. Rottler obtained nearly 24 tons of wood chips and mulch to begin the on-site composting process. An existing on-site cement pad was used as the foundation for the pile. After the pile was in place, clean-up of the site began. Wood chips, mulch, straw and the animal fatalities were placed on the pad and a straw bale berm was placed around the perimeter of the pile to prevent run-off and leaching. After weeks of site monitoring by both IDNR and Codner, temperatures reached 140° F - the temperature needed for decomposition. "The composting appears to be effective," states Rottler. "I'm thankful that we were able to keep the carcasses out of the landfill and expectant that we will gain a viable soil amendment for our crops. I am also pleased that by working with Eric Wiklund (IDNR, Field Office #2) and Shelly Codner (IWE, Area C), at least one positive thing has come from this horrible devastation. I appreciate their expertise and professionalism." Both IDNR and Codner will continue to monitor the project, track decomposition and ultimately record yields from the amended crop area.

In addition to creating a high quality soil amendment, the overall project diverted approximately 40 tons of animal fatalities and 140 tons of steel from the landfill, resulting in a direct savings of $7,200. "This is minimal to the overall loss," states Rottler, "but it certainly does help."

Ritchie Industries Makes a Match with China
By Sarah Craft
IWE Resource Specialist

Since 1921, Ritchie Industries in Conrad, Iowa, has manufactured high-quality animal and livestock watering equipment. Today, the company produces over 40 models to meet farming needs throughout the country. Similar to other manufacturers, Ritchie Industries pays to throw away by-products and waste materials generated through daily production. More often than not, many of these materials could be easily recycled or reused by a second company as a raw material. By doing so, manufacturers save money through reduced landfill fees while the second company sees a savings by incorporating used materials into their own production process. It is a win-win situation for both parties, but occasionally, an unusual material creates a recycling challenge.

Ritchie Industries products include high quality polyurethane foam encased in polyethylene plastic. The company has made it a priority to provide the finest watering equipment to its customers, so any product with a possible defect is tossed into a grinder and transformed into a clean blend of foam and plastic. Due to the high cost of landfilling and potential recycling options, Ritchie Industries has opted to store the ground material and search for a reuser.

With continued research and a group effort, Ritchie Industries finally made a long-awaited match. Larry Cole, Ritchie Industries, Sarah Craft, Iowa Waste Exchange specialist, and Eric Williams, V.I.M. Corporation, located a plastic recycler in China, willing and able to slowly incorporate the plastic and foam blend into their molding process. At approximately one Gaylord of material a month and 1,000 pounds of the blend in each Gaylord, this joint effort will keep 12,000 pounds of polyethylene plastic and urethane foam out of the landfill and into the plastic goods we use daily.

From Plastics To Pallets
By Julie Plummer
IWE Resource Specialist

Greystone Manufacturing, LLC, located in Bettendorf, IA, manufactures plastic pallets for the beverage industry. The plastic pallets are made entirely from post-industrial and post-consumer high density polyethylene (HDPE), polypropylene (PP) and polyolefin (TPO) plastics.

In order to fulfill monthly orders, 2 million pounds of recycled plastics are required (in the form of raw material) for the company's molding process. The recycled plastics needed are obtained directly from other businesses who generate waste plastics and from collectors and processors of these materials within Iowa and throughout the United States. During the last four years, Greystone's production has grown and continues to do so. In 2007, it is projected that Greystone will use 50 million pounds of recycled plastic, a jump from the current use of 3 million pounds annually.

Recently, Greystone has undertaken an expansion to produce a new type of plastic pallet that will require an additional 1.5 million pounds of PP per month, as well as create 15 new production jobs. For this new product, Greystone will focus on the use of plastic automobile bumpers. The company would like to maximize the amount of PP used (bumpers and other forms) from Iowa sources. Iowa Waste Exchange Area D Resource Specialist, Julie Plummer has worked with Greystone in the past and is now actively involved in helping the company locate even more sources of recyclable plastics in Iowa, helping the Iowa Waste Exchange divert solid waste from Iowa landfill disposals.

"This project," says Greystone’s Jim Strieck, "eliminates many of the barriers in the re-utilization of waste plastic materials by providing an on-going market for generators and processors of plastic, by managing and reusing these waste materials through production of a marketable product and by altering attitudes of both generators and end product users. Each new recycled pallet introduced displaces wood pallet use, counteracts deforestation and fosters sustainable behavior."

The Iowa Waste Exchange is a cooperative effort of Recycle Iowa/ Iowa Department of Economic Development, the Iowa Waste Reduction Center, the Iowa Department of Natural Resources, Iowa Community Colleges, Local Councils of Government and Iowa Solid Waste Agencies. The Exchange will not determine what may constitute a hazardous substance or create a hazardous situation. The Exchange will not make judgments with respect to any legal requirements, particularly for the storage, transportation, treatment or disposal of what may be defined as hazardous substances. For information about hazardous waste reduction and/or proper disposal, call the Department of Natural Resources Energy and Waste Management Bureau at (800) 367-1025 or the IWRC at (800) 422-3109.

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© Copyright 2007 Iowa Waste Reduction Center
A Service of Business and Community Services at the
University of Northern Iowa
Suite 113, BCS Building
Cedar Falls, IA 50614-0185
phone: 319.273.8905
fax: 319.273.6582