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HomeMy WebLinkAbout2015-03-05 Memo - Operations 1 MEMORANDUM TO: File FROM: Carl E. Lawson, Jr., Hazardous Waste Inspector SUBJECT: Operations Kaleidoscope Imprints 103C Mid Tech Drive DATE: March 5, 2015 Production Operations 1) Emulsion (a semi-solid material) is applied manually with a scoop to print screens with excess reclaimed and put back into the original container. 2) A film is then placed over part of the emulsion-covered print screen. 3) The emulsion is then cured by placing the emulsion-covered print screen onto a special table, sealing it in place with a cover and then exposing it to a special light. The emulsion covered by film does not cure. 4) The uncured emulsion is then washed off of the print screen revealing the design. The washing is done manually in a dedicated booth, over a basin that is on a spill control pallet with all wash water retained in a drum for removal by a hazardous waste hauler. The water is recycled numerous times before removal. 5) The print screens are then allowed to dry in a rack. 6) Ink (also a semi-solid material) is then applied to print screens at print stations with excess ink wiped away and put back in the original container. 7) Once they are through being used at the print stations, the print screens are cleaned of both ink and cured emulsion by the semi-automatic Dane brand DW 125 model print screen reclaiming unit. 8) First, the ink is cleaned from the screens by the Dane machine using a solvent that is stored in a reservoir within the machine. The solvent for ink cleaning remains in the machine during use. 9) Second, the emulsion is cleaned from the screens by the Dane machine using an emulsion (a.k.a. stencil) remover concentrate and water solution. This solution recirculates numerous times through a closed-loop system that includes the machine, lines and an adjacent 275-gallon Intermediate 2 Bulk Container (IBC). (The Dane unit and the IBC are both inside a concrete containment area). 10) The print screens are then allowed to dry before being used again beginning with the emulsion application described in Step 1. **** Print screens that will be reused with the same design are cleaned of ink in a dedicated room that: is used for ink removal only; is itself a concrete bermed area; has a parts wash type basin from which solvent recirculates from a drum; has explosion-proof wiring and an exhaust fan. This process leaves the cured emulsion design on the print screen so that the same design can be used again. Fresh Water Introduction to Print Screen Reclaiming Process Once the emulsion remover and water solution is no longer usable and is removed by Safety Kleen fresh water is introduced to the system by manually operating a faucet that has a backflow preventer in place. A hose is attached to the faucet and run to the system for filling. The introduction of fresh water is done about twice per year. HAZARDOUS WASTE REMOVAL Manual Uncured Emulsion Wash Station The waste water solution is recycled numerous times before disposal by Safety Kleen. The solution is pumped from the small drum by Safety Kleen. Print Screen Reclaiming Unit Emulsion Wash Solution The solution is recycled numerous times before disposal. The solution is pumped from the primary IBC to a secondary IBC that is outside of the containment area once it is no longer usable. This secondary IBC is then immediately removed from the property by Safety Kleen, a hazardous waste hauler. The reason for pumping the used emulsion wash solution from the first IBC to the second IBC is because it is more cost-effective for Safety Kleen to remove an entire full IBC than to pump one out and it is not possible to remove a full IBC from the containment room as it would have to be lifted over a 3.5” high concrete berm. Kaleidoscope learned it would take Safety Kleen two hours to pump out an IBC and the time is billable. Solvent 3 The solvent is recycled numerous times within the machine before disposal. The solvent is removed from the machine reservoir and disposed of by Safety Kleen once it is no longer usable. Dedicated Ink Removal System Safety Kleen also removes used solvent, sludge and filters from the dedicated ink removal system which is inside the dedicated ink removal room which is also a concrete containment area with explosion-proof wiring.