APPENDIX C, U.S. EPA Facility Pollution Prevention Guide, EPA/600/R-92/088
CUSTOMIZED POLLUTION
PREVENTION WORKSHEETS

         The worksheets in this appendix were taken from the manual
Guides to Pollution Prevention:  The Pharmaceutical Industry (see
Appendix G).  These worksheets illustrate how personnel at a
plant might customize the Pollution Prevention Worksheets in Appendix 
A to fit a specific industry or facility.  For a full description 
of waste minimization assessment procedures, refer to
the text of this manual.

Case Study -
Example Pollution Prevention 
Opportunity Detailed Assessment

         This study illustrates a pollution prevention assessment done
by a small pharmaceutical company.  This example is based on
actual experience but uses fictitious names, processes, and data. 
The case study uses industry-specific worksheets and covers
detailed assessment activities from forming an assessment team
through screening options.  
         The ABC Pharmaceutical Company, Inc., is a small production
facility.  Its main product is a low-volume, high-value-added
protein solution product.  ABC also manufactures a high-volume,
low-value-added saline solution product.  The growing cost of
waste disposal and the small margin of profit on the saline
solution product led management to institute a pollution preven-
tion program.
         A pollution prevention task force was assembled.  It consisted
of:
          A process engineer
          A product engineer
          A process area supervisor
          An environmental compliance 
          specialist
The process engineer was the team leader and the corporate pollu-
tion prevention champion.
         
The team met and established the following goals:
          Achieve a significant reduction in the generation of haz-           
           ardous wastes.
          Identify data sources and deficiencies and work toward devel-           
           oping reliable means of measuring reductions.
          Maintain product quality.
          Maintain or improve profit margin of saline solution in light
           of increasing waste disposal costs.
         The task force assembled as much data as possible on those
operations that use toxic chemicals or generate hazardous waste. 
This included preparing block diagrams of several key processes. 
They found that, aside from purchase and shipping records and
regulatory reports of releases, there were few records on
hazardous materials.  They were unable to prepare complete mass
balances for any of the key processes but were able to identify
the major waste streams.  The mass balances also identified
additional data that would increase understanding of the process
operation without extensive new data collection.
         The data gathering focused on waste sources, material-handling
practices, input materials, and products.  The effort started
with these inputs because they were the areas most likely to
yield pollution prevention opportunities and because they had the
most available data.  The major data sources were purchasing re-
cords, waste shipment manifests, material safety data sheets,
product specifications, Superfund Amendment and Reauthorization
Act (SARA) reports, and conversations with the production area
workers.
         The team also prepared a description of the key processes in
the plant (aqueous cleaning, disinfecting, venting, general
housekeeping, chemical synthesis, and research and development). 
They then described and prioritized the waste streams.
         After collecting and reviewing the plant data, the team held a
brainstorming session to generate pollution prevention options. 
Several pollution prevention options were identified and selected
for future feasibility study and possible implementation.


Worksheet Titles

Worksheet 1.                      Waste Sources
Worksheet 2.                      Waste Minimization:
                                     Material Handling
                                   (2a, 2b, and 2c)
Worksheet 3.                      Input Materials Summary
Worksheet 4.                      Products Summary
Worksheet 5.                      Option Generation:
                                     Material Handling
Worksheet 6.                      Process Description
                                     (6a, 6b, 6c, 6d, and 6e)
Worksheet 7a.                     Waste Stream Summary
Worksheet 7b.                     Waste Description
Worksheet 8.                      Waste Minimization:
                                     Reuse and Recovery
Worksheet 9.                      Option Generation:
                                      Process Operation
Worksheet 10.                     Waste Minimization:
                                     Good Operating Practices
Worksheet 11.                     Waste Minimization:
                                         Good Operating Practices
  
(The worksheets are deleted from this electronic version of this manual.  
 For a printed copy of U.S. EPA's Facility Pollution prevention Guide, 
 EPA/600/R-92/088, please contact U.S. EPA Pollution Prevention Researech
 Branch by phone: 513/569-7215 or FAX: 513/569-7111.  A copy may also be 
 requested from Ohio EPA, Office of Pollution Prevention by calling 614/
 644-3469 or by FAX: 614/728-1245.)