Pollution Prevention Tips

Additional Information

KEYS TO POLLUTION PREVENTION IN AN AUTO REPAIR SHOP

· Managers must be committed for it to happen.
· Know the types of waste you generate.
· Know how much it costs to manage your wastes.
· Prevent spills and leaks.
· Avoid having out-dated supplies - computerize inventory.
· Properly label containers.
· Provide employee incentives to reduce wastes.
· Properly accumulate and store wastes.
· Train all of your employees in waste management.
· Train all your employees in pollution prevention.
· Keep up to date on new technologies.

· REDUCE YOUR COSTS FOR RAW MATERIALS
· LOWER YOUR LONG-TERM LIABILITY
· REDUCE YOUR WASTE TREATMENT, TRANSPORTATION AND DISPOSAL COSTS
· INCREASE YOUR INCOME BY SELLING OR REUSING YOUR WASTE
· HAVE FEWER COMPLIANCE REQUIREMENTS WITH REDUCED WASTE
· LOWER YOUR RISKS FOR ACCIDENTS, SPILLS AND EMERGENCIES

Some final Tips on Pollution Prevention

As autobody shop owners and operators, you can save money, protect the environment, reduce your liability and compliance costs and decrease worker and public safety risks.

Used Oil
· Prevent spills with drip pans. Mop up spills with rags that can be laundered.
· Install "oil extender" filters.
· Recycle used oil.
· Separate oil from other wastes.
· Avoid oils with chlorine or fluorine.
· Accept uncontaminated used oil from customers.
· Encourage the use of high-performance, longer lasting oil and oil filters.
· Extend oil life by ultrafiltration.

Spent Oil Filters
· Fully drain oil filters.
· Recycle oil removed from the filter.
· Recycle filters as scrap metal.

Batteries
· If unbroken, sell batteries to recyclers.
· Store batteries indoors in temperature controlled secondary containment.
· Use longer life batteries

Carburetor Cleaning Wastes
· Do not mix with used oils.
· Use reformulated products.
· Utilize cold dip carburetor cleaners.
· Purchase non-aerosol cleaners.
· Collect excess cleaning fluids, separate particles and reuse.

Tires
· Extend tire life by properly inflating and rotating.
· Recap and resell.

Waste gasoline
· Filter and reuse.

Radiator Wastes
· Remove solids from alkaline solutions and reuse water.
· Collect flushing fluids and reuse.

Waste antifreeze
· Recycle waste antifreeze

Brake waste
· Use asbestos-free brake shoes.
· Use water as a brake cleaner.
· Use lighter-weight synthetic absorbants.

Use different raw materials
· Use recycles and recyclable petroleum products.
· Use waterless hand cleaners.

Exhaust emissions
· Encourage the maintenance of engine emission canisters to reduce fuel loss.

Keep in mind that
· One litre of oil can contaminate a million litres of water; used oil from a single oil change can ruin a million gallons of fresh water - a year's supply for fifty people.
· Antifreeze spills can enter the groundwater stream and sewer system and pollute drinking water.
· If swallowed, small amounts of antifreeze are poisonous to people and wildlife.
.

How to Prevent Pollution in Your Daily Operations

This page and the following contain lists of tips, which you should keep in mind while conducting your daily shop operations. Post the first page in your shop and the second in your office as constant reminders of good environmental and cost-saving practices.

Pollution Prevention

· Switch to detergent based cleaning solutions.
· Use safer or less hazardous solvents.
· Use drip trays and allow more drainage time.
· Use dry pre-cleaning methods, such as wire brushing.
· Do not contaminate chlorinated solvents with water.
· Promptlyfilter out solids.
· Use dirtier colvent for first cleaning.
· Use ultrasonic or mechanical agitation.
· Convert free running rinses to still rinse.

In doing that you will:

· Reduce your costs for raw materials.
· Lower your long-term liability.
· Reduce your waste treatment, transportation and disposal costs.
· Have fewer compliance requirements.
· Lower your risks for accidents, spills and emergencies.

Keys to Pollution Prevention in an Autobody Shop

· Ensure that you and your management team are committed to pollution prevention.
· Know the types of waste you generate.
· Know how much it costs to manage your wastes.
· Prevent spills and leaks.
· Avoid having out-dated supplies by computerizing your inventory.
· Label containers properly and clearly.
· Provide employee incentives to reduce wastes.
· Train all of your employees in pollution prevention.
· Keep up to date on new and innovative technologies.
· Implement an Environmental Management system that is clear, simple, documented and well understood by all staff.

In doing the above you will:

· Reduce your costs for raw materials.
· Lower your long-term liability.
· Reduce your waste treatment, transportation and disposal costs.
· Increase your income by selling or reusing your waste.
· Have fewer compliance requirements.
· Lower your risks for accidents, spills and emergencies.

The Benefits of Good Environments Management in Bodyshops.

Written by John Norris

The moment the words "environment" or "legislation" are mentioned to autobody shop owners, you can expect them to roll their eyes toward heaven as if seeing their profit dollars floating up to the clouds.

LET'S LOOK AT SOME REALITIES.

Environmentally conscious shop owners are:

a) Attracting the more environmentally conscious consumer to their shop, and giving their shop a competitive advantage.
b) Marketing their community concern in their advertising.
c) Saving money on recycling costs and disposal costs.
d) Encouraging higher environmental surcharge fees from insurers.
e) Creating a professional image.
f) Delaying or eliminating the need for more restrictive laws, zoning regulations or legislation.
g) More likely to get bank loans and satisfactory land use decisions.
h) Likely to have higher door rates honoured.
i) Able to work on newer paint technology vehicles.

WHAT DOES THIS MEAN FOR ME AS A SHOP OWNER?

Recycling your cardboard and putting it out on the curb for pick-up would save the costs of a special bin (One Hamilton shop saves $360 a year doing that).

Using a solvent recycler regularly (A Hamilton shop has cut his purchases by $2000 a year and his disposal costs by $2200 a year.)

Charging for an environmental surcharge (A recent survey showed that 60% of shops in our area charged, and were having honoured, a surcharge of $7.00 per w/o. This would cover the average shops $3000 per year annual disposal costs.)

AUTOMOTIVE PAINT SHOPS - *Waste Reduction Fact Sheet*

Many companies have gone beyond minimum regulatory requirements and have implemented a waste reduction program. In general, waste reduction can improve the efficiency of your operation while reducing its environmental impact. Benefits include:

* Reduced material waste, waste handling and disposal costs

* Reduced environmental risk and liability

* Improved workplace environment and health and safety (fewer lost person - days and reduced workers' compensation costs)

* Improved company image (marketing advantage)

* Improved process efficiencies, productivity and bottom line benefits

The province of Ontario has set a goal of 50 per cent diversion of waste from disposal by the year 2000. For current information on the Ministry of Environment's regulations affecting business waste disposal, call 1-800-565-4923

General

* Establish a preventative maintenance program for all equipment

* Set up a spills program and train all employees in good housekeeping procedures, spills prevention and spills management

* Segregate all wastes to reduce cross contamination, improve recyclability and minimize the volumes of hazardous wastes and their disposal costs

Reduce

* Turn off solvent streams and cover solvent tanks to reduce evaporation when they are not in use

* Implement rigit inventory controls including a "first-in, first-out" inventory system, to use the oldest stock first, particularly for products with a limited shelf life.

* Avoid over purchasing of materials to avoid waste

* Rework spilled materials back into the process, when feasible. Otherwise use absorbents for spills clean-up and dispose contaminated absorbents properly. Never wash spills into floor drains.

* Whenever possible, substitute hazardous materials with non-hazardous alternatives such as replacing solvent cleaners with water-based cleaners or substituting detergent-based solutions for caustic solutions

* Check all vehicles for fluid leaks and use drip pans to prevent spills onto the floor and into floor drains.

* Avoid unnecessary equipment cleaning

* Use low / no VOC paints and coatings wherever feasible (eg. water-based, high solids, powder coatings, etc)

* Promote your 3Rs program to the public and your customers to gain a competitive edge

* Turn off all lights and equipment, when not in use and turn down the thermostate after hours.

* Investigate alternatives to solvent-based paint strippers, e.g. dry stripping methods with abrasive media

* Train employees on efficient paint application techniques and provide efficient paint application equipment such as High Volume / Low Pressure (HVLP) spray guns

* Use glycerine-based "liquid masking" to reduce paper masking waste and to save time

* Use self-curing paints to reduce baking oven use to conserve energy

* Estimate, measure and mix the paint required for a given job as accurately as possible and prepare only as much as is necessary

Reuse

* Return or donate excess or oil spec paints to your suppliers or to charitable organizations or give them to your customers for use in touch-ups. This material is also available from your local municipality or waste exchange

* Work with suppliers to cut down on or use reusable packaging

* Contract a linen and laundry supply service to provide towels and rags for cleaning purposes

* Return containers to the suppliers for reuse or examine methods of reusing or recycling containers yourself

* Reuse spent solvents as a precleaning solution or rough prestrip, before using virgin solvents. This will extend the life of your solvents.

* Install a drying rack and / or drip pan to collect solvents running off washed parts, Then reuse the solvents

Recycle

* Segregate all waste materials to minimize contamination, spills or evaporation and to increase their recycling potential

* Contract, purchase or lease a collection and recycling service for solvent bath liquids. This will lead to an immediate reduction in disposal and raw material costs

* Standardize solvent usage

* Recycle paint overspray

* Talk to your municipality, hauler or local recycling company about setting up a recycling program for all solid non hazardous wastes including line paper, cardboard, plastics, glass and wood. Encourage employers to take blue box materials home

* Purchase materials that can be easily recycled and / or contain recycled content

The following outlines the information typically required in the preparation of an MOE Application for Approval (Air) for an automotive paint spray booth and associated equipment:

1. The maximum paint application rate, in litres per hour, for each of the principal coating types in use (e.g. primer, acrylic, basecoat, clearcoat) for each paint spray booth or prep station on-site.
(typical maximum range is 1.0 to 2.0 litres /hr of coating for the worst case complete repaint)

2. As sprayed mixing ratios of each of the principal coating types with their respective reducers and or hardeners, along with safety data sheets for each material. (Example DC92 clear / DH46 hardener / UR50 reducer - 3:1:1)

3. A layout drawing of the booth indicating its configuration (downdraft, crossdraft), the interior dimensions and the location and area of the paint arrestor filters or water wash chamber on the exhaust.

4. Exhaust fan specifications including type (vaneaxial, tubeaxial, centrifugal), diameter, volumetric flowrate and static pressure. (Note: If not available from supplier info, provide all details from rating plate on fan / motor housing)

5. Exhaust stack parameters including height above the roof deck, height above ground level, diameter at exit and the type of stackhead (e.g. velocity cone, rain ring). (Sketch if necessary)

6. If the booth is equipped with a heater for a cure cycle, the maximum thermal input rating of the burner. Exhaust fan and stack parameters should also be included if the booth vents through a separate stack in bake mode.

7. A scaled site plan indicating the location of the building relative to all property lines and a scaled elevation plan indicating the height of the roof deck above grade level. Alternately, this height may be indicated on the site plan if the building has a flat roof. (If hand drawn, please ensure all dimensions are accurately measured)

8. If the shop is housed in a unit of a multi-tenant building or commercial mall, a roof plan, to scale, indicating the location of the stack(s) relative to any roof mounted air intakes or HVAC equipment serving neighbouring units. If there are no intakes on the roof, the distance from the stack to the neighbour's nearest openable door or window should be indicated on a plan or sketch.

9. If the shop is housed in a unit of a multi-tenant building or single occupant building rented by the shop owner, written consent from the landlord to allow the operation of the subject equipment.

10. An up-to-date land use zoning plan of the surrounding area (available from the local municipal planning department), indicating the location of the site relative to areas of residential land use.

11. A scaled area location plan of the surrounding neighbourhood (available from the local municipal planning department), indicating the locations and nature of use of adjacent buildings and locations of the nearest residential, hospital and/or school buildings. In the case of spray booths equipped with tall stacks (stack height above the roof is greater than the roof height above ground), the locations and heights of neighbouring buildings taller than the stacks must also be noted.

12. Articles of Incorporation or other documentation setting out the proper legal name of the company. Sole proprietorships registered under the Business Names Act must be supported by a copy of the proprietors drivers license or birth certificate.

HVLP Background Information

Painter Technique

Possibly the single biggest factor in any spray equipment's transfer efficiency is the person operating it. From mixing the paint and solvents correctly to adjusting the spray pattern size to pointing the gun accurately, the painter has the responsibility of making the equipment perform. For many shops that bought an HVLP spray gun and began using it with no training at all, the results have often been disappointing.

Painter technique plays a big part in TE. Aiming the gun carefully helps get all the paint on the car, and changing the pattern size of the spray gun while you paint can save a lot of material. The key is to receive training with the guns in your own shop's own shop. Painters who have seen the trainer achieve a properly atomized finish using the shop's own brand of paint know first hand that the equipment will work. Painters who have only seen the rough looking finish that they are able to produce on their own, without any training, are sure that the problem is with their spray gun.

HVLP equipment is different from standard issue siphon feed guns, so a willingness to change your procedures to achieve maximum performance is essential. For example, most painters using conventional spray guns move their hand about two feet per second. But HVLP works better at about half that, at a hand speed of about one foot per second.

With HVLP the painter needs to be closer to the surface to be painted. The 8 to 12 inch gun distance most painters now use has to be about 1/3 closer or 5 to 8 inches from the surface. This combination of the slower speed and closer distance makes many painters feel as though they're going to run the paint off the car. They soon become comfortable with the process, however, after seeing results.

As mentioned earlier, pressure feed HVLP spray guns are different from siphon guns. To get more fluid delivered to the tip of a siphon gun, more air is blasted past the tip to create a better vacuum. In gravity feed guns, the fluid delivered is limited by the pull of gravity and how much pint remains in the cup.

Pressure feed equipment allows you to vary how much paint arrives at the fluid tip to suit your painting style, and it is this control over adjustments and variables that allows painters to spray different products successfully. For example, basecoats generally require both low pot pressure (fluid speed) and low atomization pressure (low over spray). These added controls make for material savings and a quality finish.

If you haven't used HVLP spray guns before, begin with the basecoat. One of the experts consulted said it was so easy that almost anyone could make a basecoat look good. Getting a great looking clearcoat sprayed is achievable with more practice.

On the other hand, spraying a "tack" coat with an HVLP gun is a mistake. Because the droplet size is large and has no impact effect to help it flatten out, and since the droplets land for apart when applied dry, the tack coat dries rough and cannot be reflowed by subsequent coats. Always spray a medium wet coat first with a slower than normal reducer to get the finish to level out.

One reason for the slow acceptance of HVLP is fear; painters have heard that it won't work. If you do not change
reducers, do not have enough air or move too fast, it won't work. Proof that it dies work, however, is the thousands
of painters who get great looking HVLP clearcoat jobs while using 30% less material.

Air Errors

You need a lot of clean, dry air to properly operate HVLP equipment. A big problem for many shops is the quality of their air supply.

Dry regulated air is especially important to these guns. Unless your regulator functions properly and delivers an even volume of air, the gun's performance will be lowered. Moisture in compressed air lines can cause a reaction with the isocyanate hardeners used in many clears, and the thicker, slower flashing coat of paint that an HVLP gun lays down could make the water and isocyanate problem worse.

Lack of adequate air volumes can make the use of HVLP problematic. A helpful rule when calculating air
volume is that for each horsepower on the electric motor running the compressor, expect the compressor to produce about four cubic feet of air per minute.

The most common air compressor in body shops is a 5hp/80-gallon tank. This compressor will deliver about 20cfm (4cfm x 5 hp =20cfm). However, the amount of that volume that actually arrives at the end of the line where the HVLP gun is connected may be much different. A small diameter on anything will restrict airflow - imagine 6 lanes of traffic heading for a two lane bridge. Small airlines, small air hoses, lots of couplers and cheater valves all serve to restrict airflow to the gun. When HVLP spray guns cannot get the high volume they require, the resulting finish quality will not be very good.

Most HVLP gun offerings fall within a range of volume required from 10 cfm to 30 cfm. The average HVLP gun is used between 15 cfm and 20 cfm. Powering the 20 cfm gun requires the use of all the air from the average shop compressor. If someone else fires up an additional air line the gun will start to fluctuate and atomize poorly. If you cannot afford a bigger compressor, purchase a smaller fluid tip and/or air cap for your present HVLP gun. Many shops believe that their HVLP problems result from the gun, when, in fact, they are caused by a lack of air.

Reduction of the paint is another area which influences the ability to spray a saleable finish with HVLP guns. The lower pressures used by these guns cannot break the paint up as small as the 60 psi blast from a siphon gun. In fact, the average HVLP gun produces a particle size about as large as a conventional spray gun.

When using HVLP it is necessary to slow sown the solvent evaporation speed. Since the droplet is not small enough, you need the solvent to stay in the film long enough to melt the droplets into each other. All other spray conditions being equal, slow your solvent by one temperature range when using HVLP equipment.

Many HVLP users try to fix the flow problem by simply adding more fast solvent. Not only does this defeat and legislation's purpose is using high TE spray guns, it also does not solve the orange peel problem. Precise control of the product mix is always important. In fact, when using HVLP this control is critical. Changing solvent and catalyst speeds to accommodate the equipment is necessary.

Good Shop Practices to Reduce Wasted and Costs

Suggested Practices for Containers

· Use a minimum of non-returnable containers.
· Ship and store containers with lids and openings tightly sealed.
· Handle non-returnable containers as returnable containers to minimize losses.
· Ass a small portion of thinner to empty containers to minimize residual material.
· Process empty containers promptly as hazardous waste.

Suggested Practices for Spray Cleaning Equipment

· Clean guns using approved spray gun cleaning equipment at gun cleaning stations.
· Post instructions for the proper use of gun cleaning equipment at gun cleaning stations.
· Monitor the proper use of gun cleaning equipment.
· Keep cleaning solvents in sealed containers between uses.
· Send gun-cleaning solvents for recycling or in-house recycling.
· Clean other areas and parts with low-VOC release methods (brushes, wipers, etc.)
· Control access to solvents used for cleaning and closely monitor their usage.
· Use non-VOC strippers and cleaners where feasible.
· Store and send (for disposal) used cleaning equipment and fluids in sealed containers.

Suggested Practices for Other Equipment Cleaning

· Post approved cleaning practices.
· Use non-VOC content cleaners where possible.
· Store cleaners in containers while waiting to be recycled or disposed of.
· Recycle used cleaners wherever possible.

Suggested Practices for Spray Booth Cleaning

· Use specific, written cleaning procedures.
· Conduct regular inspection and maintenance of air supply as necessary.
· Maintain application equipment for minimum over spray.
· Plan cleaning schedules to minimize cleaning cycles.
· Clean other areas with low-VOC methods (brushes, wipers, etc.)
· Store VOC-containing cleaning equipment and materials in controlled access cabinets.
· Control access to solvents used for cleaning and closely monitor usage.
· Use non-VOC strippers and cleaners wherever feasible.
· Store and send (for disposal) used cleaning equipment and fluids in sealed containers.

VOC's - Volatile Organic Compounds

Everyone has some concern about their environment, whether it involves their own love of nature, the future of their children, or the security of their business. Pollution is a problem, and many industries have been targeted as significant sources of VOC emissions and the automotive refinishing industry is one of them.

Solvent used in automotive refinish paints are classified as Volatile Organic Compounds (VOC's) There are great concerns with VOC's because they react with sunlight and generate ozone and other pollutants generally referred to as "photochemical smog." Regulations are up and coming province-wide as they are well established in the U.S to limit air pollution.

The solvents used in the collision repair certain inherent characteristics which make them useful for paint application but unfortunately harmful to the environment. Solvents, (VOC's), evaporate at room temperatures, vaporize when sprayed or exposed to air and decrease stratospheric ozone while increasing ground level ozone. Stratospheric ozone is critical to us, protecting the Earth from the sun's radiation, however ground level ozone (smog), is hazardous to human health and does not rise to the stratosphere where it would be beneficial.

To address the problem of excessive VOC release, there are several equipment and shop practice recommendations for collision repair facilities. High transfer spray equipment can be used along with enclosed spray gun cleaners. Solvent should be stored and recycled in closed containers, as should soaked rags, papers and cloths. There is also a need for consistent records concerning VOC use.

The use of high transfer efficiency equipment applies more paint to the surface, wastes less in overspray, and reduces VOC emissions. To meet required efficiency, at least 65% of the material sprayed must remain on the vehicle. Both high volume / low pressure (HVLP), low volume / low pressure (LVLP) sprays and electrostatic applications meet this desired efficiency for shops.

The above recommendations provide the shop with the advantages listed below:

- fewer VOC's are released into the air
- healthier work environment is created because less overspray, solvents, and other related chemicals are being released into the air
- lower VOC emission promotes compliance to the Occupational Health and Safety Act and WHMIS provisions, less costly WCB penalties as well as better employer-employee relations
- fewer materials are required to complete repairs
- less surface contamination from dust and dirt that is dislodged by high pressure air in the spray booth
- painter suits stay cleaner and last longer

Good VOC records require the documentation of several items such as: the number of refinishing jobs performed each day; the names, quantities, and VOC content of materials used; and the mixing ratios and VOC content of materials as they are applied. Material Safety Data Sheets (MSDS), can labels or wall charts may be consulted to determine the VOC content of all products. These VOC records should be kept for at least two years.

No part of this document may be reproduced without the permission of Hamilton District Autobody Repair Association

HVLP Spray Guns: Cost-Effective, Environment-Friendly Technology

SAVE $$$ ON PAINT - PROTECT YOUR HEALTH AND THE ENVIRONMENT - REDUCE PAINT OVERSPRAY AND EMISSIONS

Why should you use high-volume low-pressure (HVLP) spray guns?

Paint spray contains harmful chemicals such as isocyanates, solvents, and paint additives. Painting with an HVLP spray gun significantly reduces overspray and as a result:

Releases of toxic chemicals into the air go down, helping protect you, your co-workers, and your shop's neighborhood.

The amount of paint you need to refinish a car goes down, saving your shop many dollars in paint costs

This graph highlights the dollar savings auto refinishing shops can realize in switching from conventional to HVLP spray guns. If painters use proper spray technique and gun settings, savings nearly double. Estimates are based on data from the STAR program* at the Iowa Waste Reduction Center, for a shop that refinishes 15 cars per week.

* Contact the Spray Technique and Analysis Research (STAR) program at the Iowa Waste Reduction Center (1-800-422-3109; www.iwrc.org) for technical assistance.

Can you achieve a high-quality finish using HVLP spray guns?

Yes! Painters at many auto shops use only HVLP spray guns when refinishing cars, without sacrificing the quality of the finish, even for top coats. Of course, you'll need to make some technical adjustments to your pressure settings and spray cap when converting from a conventional spray gun to an HVLP spray gun. But once you do, you'll find that HVLP spray guns are relatively easy to use, reduce overspray, and produce a high quality finish.

How can I get more information on HVLP spray guns, proper spray techniques, hazard controls, and other resources?

Contact the Spray Technique and Analysis Research (STAR) program at the Iowa Waste Reduction Center at 1-800-422-3109 for technical assistance.

Talk to your jobber, paint distributor, or equipment supplier.
Consult with the National Institute for Occupational Safety and Health (NIOSH) by either visiting their Web site or calling 1-800-35-NIOSH.

Talk to Mary Cushmac (202-260-4443; cushmac.mary@epa.gov) or David DiFiore (202-260-3374; difiore.david@epa.gov) of the DfE Project Team.