United States National Risk Management

Environmental Protection Research Laboratory

Agency Cincinnati, OH 45268

Project Summary

Research and Development EPA/600/SR-96/113 September 1996

As part of its Waste Reduction Evaluation at Federal Sites (WREAFS) Program, the U.S. Environmental Protection Agency (USEPA) National Risk

Management Research Laboratory

(NRMRL) worked cooperatively with the

U.S. Postal Service (USPS) to integrate

waste prevention and recycling activities into the waste management programs at various postal facilities

through the conduct of pollution prevention opportunity assessments

(PPOA). The PPOA summarized here

was conducted at the USPS Northern

Virginia Facilities located in Merrifield,

VA.

The PPOA documented and quantified waste generation at Engineering,

Research and Development (ERD), the

Processing and Distribution Center

(PDC) and the Vehicle Maintenance Facility (VMF). The report makes recommendations concerning the procurement of office supplies, maintenance

supplies and hazardous materials; management of hazardous materials and

wastes; purchase of chemicals on

USEPA’s 33/50 list; improvement of

source separation and recycling of paper and paper products, metals and

plastics; management of unwanted

equipment; and other options for reducing or eliminating pollution.

This Project Summary was developed

by USEPA’s National Risk Management

Research Laboratory, Cincinnati, OH to

announce key findings of the research

project that is fully documented in a

separate report of the same title (see

Project Report ordering information at

back).

Introduction

Since 1988, EPA’s National Risk Management Research Laboratory (NRMRL)

has managed a technical support effort

known as the Waste Reduction Evaluations at Federal Sites (WREAFS) Program.

WREAFS was established to provide pollution prevention solutions to environmental issues through research, development

and demonstration of pollution prevention

techniques and technologies, and transferring lessons learned within the federal

community and related private sector industries.

The United States Postal Service

(USPS), in cooperation with NRMRL’s

WREAFS program is engaged in an effort

to integrate pollution prevention and recycling activities into the waste management

programs at postal facilities. The purpose

of this project was to perform pollution

prevention opportunity assessments

(PPOAs) at Postal Service facilities, recommend implementation strategies, and

develop facility guidance that can be incorporated into a revision of the USPS

Waste Reduction Guide. The project was

funded by the U.S. Postal Service through

an interagency agreement with EPA

NRMRL.

This report describes the findings of the

PPOA conducted for the United States

Postal Service’s Northern Virginia facilities located in Merrifield, VA. The site

assessment was conducted during the

week of January 23, 1995.

Pollution Prevention Assessment

U.S. Postal Service Facilities

Merrifield, VA

Carole O. Bell, Mary Hoel, Henry Huppert, and John Nuckels
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Facility Description

The USPS Northern Virginia operations

are located in Merrifield, Fairfax County,

VA on approximately 15.5 acres of land

and include three main organizational

groups operating multiple sites within and

around the Merrifield location. The three

resident organizational groups include:

Engineering, Research and Development

(ERD), mail Processing and Distribution

Center (PDC), and Vehicle Maintenance

Facility (VMF).

Facility-Wide Opportunities

Exhibit 1 provides a summary of facilitywide pollution prevention opportunities.

Following Exhibit 1 is a more detailed

description of some of those options.

Paper

• Establish a duplex copying policy for

all multi-page documents and provide

staff with training in the use of the

double-sided function on copying

equipment. As equipment is replaced,

specify easy to use, rapid, duplex capability.

 • In office and laboratory settings, expand and encourage the use of electronic mail rather than paper memos

and distribution copies.

• Limit distribution lists. If paper copies

are necessary, circulate one memo

or report with a cover sheet indicating

distribution.

• Identify opportunities to reuse paper

and paper products. Manila envelopes

and other packaging materials are reusable for their original function; paper can be turned over and used as

scratch paper or made into message

pads.

• Encourage staff to save information

on disks rather than file copies.

Undeliverable Bulk Business

Mail (UBBM)

• Determine whether reduction or recycling is the most cost effective management practice for UBBM by performing a cost-benefit analysis to compare the combined revenues from bulk

mailing and recycling of UBBM to the

costs associated with sorting, handling, transporting and processing undeliverable mail and associated packaging.

• Reduce the quantity of UBBM managed by postal facilities by expanding

the USPS mailing list maintenance

service. Annual mailing list updates,

particularly for third and fourth class

mail, could be integrated into the bulk

mail permitting process.

Engineering Research and

Development (ERD)

Engineering, Research and Development (ERD) is responsible for the performance of engineering, chemical, metallurgical and other kinds of research and development activities for the Postal Service. These activities include development

and testing of new mail processing equipment, development and testing of new

materials and coatings for mail handling

and storage containers, chemical testing

of stamp inks and papers and installation

and testing of coatings, alternative fuel

equipment and retread tires for Postal Service vehicles. The ERD employs approximately 800 people in administrative, engineering, computer, maintenance and janitorial functions.

Exhibit 1. Merrifield Waste Sources and Pollution Prevention Opportunities

Waste or Waste Source Pollution Prevention Opportunities

Procurement Centralize procurement

Establish material tracking system

Reduce credit card purchases

Purchase products containing recycled content

Eliminate purchase of products with EPA 33/50

chemicals

Hazardous materials and hazardous Establish Hazardous Materials Inventory Control System

waste management (HMICS)

Corrugated cardboard Reduce quantity entering facilities

Use permanent mail transport equipment

Reuse corrugated containers

Recycle old corrugated cardboard

Paper Reduce paper use

Reuse

Recycle

Products containing EPA 33/50 or Deplete existing stock

ozone depleting chemicals Replace with less- or non-hazardous products

Spent solvent Replace solvent sinks with aqueous or semi-aqueous

parts cleaners

Computer equipment Repair

Donate to schools or nonprofit organizations

Recycle

Energy Establish lights out policy

Use motion sensitive lighting where appropriate

Procure Energy Star-compliant computer equipment
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Exhibit 2 presents the wastes and pollution prevention opportunities specific to

the ERD.

Processing and Distribution

Center (PDC)

The Processing and Distribution Center

(PDC) is responsible for the handling and

distribution of regular and bulk mail in the

northern Virginia area. The PDC consists

of a 443,000-square-foot facility that incorporates a mail processing floor and a

basement containing storage areas, machine shops, and equipment maintenance

and repair facilities. The PDC also contains many ancillary rooms including battery shops, Undeliverable Bulk Business

Mail (UBBM) operations, and a public Post

Office (Customer Service Center). Daily

mail processing volume of the PDC is

approximately six million pieces. Exhibit 3

summarizes the wastes sources and potential pollution prevention opportunities

for the PDC. Following Exhibit 3 is a brief

cost analysis of employing reusable

dishware and cutlery and pollution prevention options for other cafeteria wastes.

Reusable dishware and cutlery

The weekly cost of purchase of disposable food service items is $573.57. Annual cost to purchase disposable dishes,

cutlery, napkins and straws is $29,825.64.

Since these disposables represent approximately 70% of the waste generated, weekly

disposal costs for these materials can be

estimated at $104.16 for an annual disposal cost of $5,416.32. Total annual purchase and disposal costs for disposable

food service is $35,241.96.

Replacement of plates, bowls, cups,

drinking glasses and cutlery with permanent reusable substitutes would result in

savings in purchasing costs ranging from

$11,813 to $13,617. In addition, a change

to reusable food service materials could

potentially reduce solid waste generation

by as much as 70%. The PDC would avoid

$5,416 in annual disposal costs.

Additional waste prevention opportunities for the cafeteria include

• Combine the corrugated packaging

and pallets for recycling with the same

materials at the PDC loading dock.

• Separate metal food and beverage

containers and place in the metals

recycling container at the VMF.

• Separate glass and plastic food and

beverage containers and establish a

recycling option for these materials.

• Contract with a grease recycling service for grease collection and reuse.

Exhibit 2. ERD Waste Sources and Pollution Prevention Opportunities

Waste Source Pollution Prevention Opportunities

Waste inks Analytical Limit quantity received to amount needed

laboratory for testing and evaluation

Halon Computer rooms Convert to a non-halon based fire

Warehouse suppression system

Transfer excess halon to DOD

Photoprocessing Photo Lab Transfer equipment and chemicals to

chemicals another location or USPS facility

Hazardous waste Shops, labs Improve procurement, management,

tracking

Control ink inventory

Eliminate parts washer

Improve storage of chemical wastes

Exhibit 3. PDC Wastes Sources and Pollution Prevention Opportunities

Waste Source Pollution Prevention Opportunities

Pallets All areas Reduce variety, reuse, recycle

Hazardous waste All Areas Set up a secure waste storage area,

close and label all drums

Polystyrene food service (cups, Cafeteria Replace with permanent dishware

bowls, plates etc.)

Polypropylene cutlery Cafeteria Replace with reusable cutlery

Aluminum, Steel and Glass food Cafeteria Recycle

and beverage containers

Grease Cafeteria Recycle
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• Specify that beverage makeup syrups be delivered in refillable metal

canisters rather than disposable bagin-box.

Vehicle Maintenance Facility

The Merrifield Vehicle Maintenance Facility (VMF) is responsible for vehicle maintenance activities for the Northern Virginia

region. The facility employs 45 people to

maintain approximately 2,903 Postal Service vehicles, ranging in size from passenger cars to tractor trailers. Exhibit 4

provides a summary of the wastes generated in VMF operations and potential pollution prevention opportunities.

Exhibit 4. VMF Waste Sources and Pollution Prevention Opportunities

Waste Source Pollution Prevention Opportunities

Paint, paint cans, paint filters Paint booth Construct new paint booth with better

painting technology, recycle paint cans

Paper, tape Masking vehicle surfaces Use reusable templates for masking

during painting

Wastewater Wash rack Install water recirculating system

Antifreeze Shop Purchase onsite recycling unit

Used oil Shop Purchase rerefined motor oil

Exhibit 5. Cost-Saving Pollution Prevention Opportunities

Item(s) of Concern Current Practice Pollution Prevention Estimated Potential Savings

Opportunity

PDC Cafeteria Use of disposable food Replace with Savings in purchasing costs ranging

service items reusable food service items from $11,813 to $13,617, savings from

avoided disposal of $5,416 in annual

disposal costs

Pine pallets Disposed Divert for recycling More than $32,000 per year, assuming

four pulls per week at $49 per pull

plus actual landfill tipping fees

averaging $115 per load

Solvent parts Most parts washers are Replace solvent sinks Potential savings are not quantifiable at

washers solvent sinks with aqueous parts this time

washers

ERD oil water Plans for replacement Since no oil is present, Cost of tank replacement

separator and oil do not replace tank. potential savings are not quantifiable at

tank Prevent oil from this time

entering drains

Recyclables Collect aluminum, Establish one multi- Reduction in waste disposal costs based

plastic and glass food facility recycling on anticipated reduction in size and

and beverage containers, program number of waste containers and

and paper products number of pulls

Procurement of Decentralized process Centralize ordering and Eliminate expenses associated with

supplies and inventory control overstocking and disposal of expired or

materials unused materials or chemicals

Cost Saving Pollution Prevention

Opportunities

Some of the opportunities discussed in the

previous sections simply reduce the generation

of pollution, while others offer the USPS economic as well as environmental benefits. Exhibit 5 presents the pollution prevention opportunities that offer the USPS significant cost reductions in addition to reducing pollution.

Conclusions and

Recommendations

This Pollution Prevention Opportunity Assessment report documents the processes performed, wastes generated and current waste management practices at

the USPS Engineering Research and

Development facility, the Processing

and Distribution Center and the Vehicle Maintenance Facility in

Merrifield, VA. The PPOA identified

opportunities to reduce both the

quantity and toxicity of the wastes

generated by this facility and recommended techniques for implementation of those pollution prevention options.

The USPS has begun to develop

a comprehensive waste generation

and management plan and is instituting source reduction and recycling

activities in its facilities. Emissions to

air and water from the Merrifield facilities are minimal. The facility should

provide extensive attention to controlling the materials that enter the

facilities. Annual solid waste expenditures could be reduced by coordination of reduction and recycling activities.

The full report was submitted in

partial fulfillment of Contract No. 68-

C2-0148, Work Assignment No. 3-

10 by Science Applications International Corporation under the sponsorship of the U.S. Environmental

Protection Agency.
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Carole O. Bell, Mary Hoel, Henry Huppert, and John Nuckels are with Science Applications

International Corporation, Newport, RI 02840.

James S. Bridges and Theresa T. Hoagland are the EPA Project Officers (see below).

The complete report, entitled “Pollution Prevention Assessment U.S. Postal Service Facilities

Merrifield, VA,” (Order No. PB97-100044; Cost: $57.00, subject to change) will be available

only from:

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22161

Telephone: 703-487-4650

The EPA Project Officers can be contacted at:

National Risk Management Research Laboratory

U.S. Environmental Protection Agency

Cincinnati, OH 45268

United States

Environmental Protection Agency

Center for Environmental Research Information (G-72)

Cincinnati, OH 45268

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EPA/600/SR-96/113