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###  

**2004**

### Hazardous Waste

### Minimization Plan

### Pittsburgh Site

### 

#### Mission

To provide continuous improvement in the reduction of hazardous waste
generated by the Pittsburgh facility. This includes any reduction that
results in the lowering of the total volume of hazardous waste or
minimizing the toxicity of the hazardous waste or both.

**[Goal]{.underline}**

A 15 percent reduction in hazardous waste generated from 2003 to 2004.

**[Definitions]{.underline}**

**Waste Minimization -** The reduction to the extent feasible or the
hazardous waste that is generated and subsequently treated, stored

or disposed. It includes any source reduction or recycling activity
undertaken by a generator that results in either (1) the reduction of
the total volume or quantity of hazardous waste or (2) the reduction of
toxicity of the hazardous waste, or both, so long as such reductions are
consistent with the goal of minimizing present and future threats to
human health and the environment.

**Source Reduction** **-** Any activity that reduces or eliminates the
generation of hazardous waste at the source, usually within the process.

**Recycling -** A material is "recycled" if it is used, reused, or
reclaimed(40CFR261.1(c)(7). A material is "used"," reused" if it is
either (1) employed as an ingredient (including its use as an
intermediate) to make a product or (2) employed in a particular function
as an effective substitute for a commercial product (40CFR262.1(c)(5). A
material is "reclaimed" if it is processed to recover a useful product
or if it is regenerated.

**[2003 Results and 2004 Objectives]{.underline}**

**Generation** **2003 lbs.** **2004 Objectives**

**[Source]{.underline}** **[generated]{.underline}
[recovered]{.underline} [disposed]{.underline} [% reduction]{.underline}
[generated]{.underline} [recovered]{.underline} [disposed
]{.underline}**

Washes 234,506 152,429 82,077 20% 190,506 123,828 66,678

Tech 27,815 0 27,815 10% 25,034 0 25,034

Q.C. Lab 9,900 0 9,900 5% 9,405 0 9,405

## Solid Waste 1,585 0 1,585 5% 1,506 0 1,506

**TOTAL** **273,806 152,429 121,377 15 % 226,451 123,828 102,623**

**2004 Objective**

**\*[On-site generation 2003]{.underline} [% reduction]{.underline}
[2004 goal]{.underline}**

**273,806 lbs. 15% 226,451 lbs.**

  ----------------------------------- ------------- ------------- -------------
  **Pittsburgh Waste Cost             **2002**      **2003**      **2004 goal**
  Objectives**                                                    

  **100% of Cost of Disposal**        **36**        **51**        **41**

  **Net COS Write Down\***            **200**       **174**       **102**

  Actual Material Writeoff            212           205           170

  Rework Recovery                     -12           -32           -68

  **Label Writeoffs (Consumer Only)** **0**         **0**         **0**

  **20% 0f Gross Writeoffs**          **42**        **41**        **34**

  **Net Shrink\*\***                  **365**       **222**       **202**

  **Actual Batch Yield**              **25**        **-14**       **0**

  **Sub Total - Waste**               **668**       **474**       **379**

                                                                  

  **Material Waste Cost/gallon**      **\$0.212**   **\$0.155**   **\$0.120**

                                                                  

                                                                  
  ----------------------------------- ------------- ------------- -------------

\*COSR writedowns will be reduced through the efforts to eliminate
defective production as well as issuing timely dispositions for current
defective product so as to eliminate write-offs to zero value.

# Q.C Lab H.W. Minimization Team

1.  Dave Brady

2.  Bob Wilbert

Generation 2003 Objective

[Source]{.underline} [2003 lbs.]{.underline} [% Tot. Vol.]{.underline}
[% Reduction]{.underline} [Goal ( lbs.)]{.underline}

Q.C. Lab 9,900 4 % 5% 9,405

**Action Plan:**

1.  Continue to recycle raw materials and finish goods back into
    production.

2.  Re-evaluate current RM/FG retains and increase recycling
    opportunities.

3.  Review current FG and replace seasonal high volume products with out
    of season lower volume products

4.  Continue to send dirty cleaning solvents to the Mixer Washer for
    continue cleaning usage.

5.  Ensure that all lab samples get back into batches prior to disposal.

.

**[Methodology]{.underline}**

**Waste Minimization Techniques;**

***Source Reduction*:** Production changes (substitution, conservation)

Input material changes

Process Changes

Equipment, piping, or layout changes

Good operating practices

1.  Loss prevention

    -Spill prevention

2.  Management practices

3.  Waste stream segregation

4.  Improved material handling

5.  Improved production scheduling

***Recycling:*** Use or reuse

Return to original process

Substitute for another process

Reclamation

Processed for resource recovery

Processed as a by-product

**[Source Reduction Teams and Action Plans]{.underline}**

**Mixer / Equipment Clean-Up**

1.  Santino Iellimo

2.  John Inks

Generation Production 2004 Objective

[Source]{.underline} [2003 lbs.]{.underline} [% Tot. Vol.]{.underline}
[% Reduction]{.underline} [Goal lbs.]{.underline}

Washes 234,506 86% 20% 190,506

Solid Waste 1,585 1% 5% 1,506

**Action plan:**

[**Thiokol** -]{.underline}

1.  Re-establish cleaning procedures for all mixers (Back to Basics II).
    Include #37 mixer (post installation).

2.  Continue to review equipment design for areas that prohibit
    efficient cleaning. (e.g., piping on a mixer may not allow
    sufficient draining prior to washing)

3.  Focus on operator mentality for adhering to cleaning SOPs. What is
    clean enough? How much Thinner Wash should be used?

4.  Continue utilization of thinner washes. Following procedures for
    cleaning and creating TW following new formula mfg.

5.  Reduce Solid waste by eliminating spills and messes which require
    absorbents, rags, etc. for cleaning.

6.  Hard pipe resin lines to mixers to avoid pail waste at manifolds.

7.  Continue to investigate products that do not have a viable cleaning
    solvent and assign possible Thinner Wash opportunities.

8.  Utilize wash from T/T rinsing and hose washing into Thinner Washes
    or to Mixer Wash for continued use.

9.  Solicit operator feedback for source reduction ideas.

10. The addition of #37 will provide for a production strategy that will
    make larger less frequent batches of product. This will relieve
    other mixers of clean-ups following single small batches of unlike
    products being made one after another.

**[Mixer wash]{.underline} -**

1.  Continue to audit change can washes (e.g. no scraping, product left)
    and minimize solvent usage.

2.  Continue to monitor usage of dedicated change cans for mfg. like
    products in order to avoid unnecessary or excessive cleaning.

**[Plant]{.underline} -**

1.  Create/utilize a task force as a tool to investigate/administer
    reduction ideas as well as more efficient cleaning SOPs

2.  Create "per batch" operating/cleaning instructions for the Basket
    Mill.

3.  Reduce solid waste by eliminating spills and messes which require

absorbents, rags, etc. for cleaning.

**Technical Dept. Waste Minimization Team**

1.) Art Riazzi

Generation 2004 Objective

[Source]{.underline} [2003 lbs.]{.underline} [% Tot. Vol.]{.underline}
[% Reduction]{.underline} [Goal (lbs.)]{.underline}

Tech 27,815 10% 10% 25,034

**Action Plan:**

Reduce hazardous waste by:

\- Better use of Inventory Data Base for tracking on site materials in
order to:

17. Reduce or eliminate over ordering of raw materials

> orders so that the excess material is not wasted.

\- Reduce dispositions of aged material.

> \- Continue to use separate waste stream for bench

washes for the possibility of recovering the solvents

through the distillation unit.

Due to business expansion, growth in

obsolete materials will be minimized through:

\- Reducing Trial batch sizes.

\- Minimizing raw material orders.

\- Pooling streams for reworkability.