Pollution prevention applications in batch manufacturing operations

Derek W. Sykes; James O'Shaughnessy

doi:10.1117/12.516187

27 February 2004 Pollution prevention applications in batch manufacturing operations

Derek W. Sykes, James O'Shaughnessy

Proceedings Volume 5262, Environmentally Conscious Manufacturing III; (2004) https://doi.org/10.1117/12.516187
Event: Photonics Technologies for Robotics, Automation, and Manufacturing, 2003, Providence, RI, United States

Abstract

Older, "low-tech" batch manufacturing operations are often fertile grounds for gains resulting from pollution prevention techniques. This paper presents a pollution prevention technique utilized for wastewater discharge permit compliance purposes at a batch manufacturer of detergents, deodorants, and floor-care products. This manufacturer generated industrial wastewater as a result of equipment rinses required after each product batch changeover. After investing a significant amount of capital on end of pip-line wastewater treatment technology designed to address existing discharge limits, this manufacturer chose to investigate alternate, low-cost approaches to address anticipated new permit limits. Mass balances using spreadsheets and readily available formulation and production data were conducted on over 300 products to determine how each individual product contributed to the total wastewater pollutant load. These mass balances indicated that 22 products accounted for over 55% of the wastewater pollutant. Laboratory tests were conducted to determine whether these same products could accept their individual changeover rinse water as make-up water in formulations without sacrificing product quality. This changeover reuse technique was then implement at the plant scale for selected products. Significant reductions in wastewater volume (25%) and wastewater pollutant loading (85+%) were realized as a direct result of this approach.

Citation Download Citation

Derek W. Sykes and James O'Shaughnessy "Pollution prevention applications in batch manufacturing operations", Proc. SPIE 5262, Environmentally Conscious Manufacturing III, (27 February 2004); https://doi.org/10.1117/12.516187

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