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Unreviewed P2 Options
for the
Manufacturing Facility Process

Following are a set of P2 options you may wish to implement. No option is perfect for everyone, but sometimes options that have worked at one facility can work at yours. They might also serve as inspiration.

Unreviewed Options for Manufacturing Facility

Following are a list of options that have been submitted by users of the pollution prevention planner. They have not been reviewed by pollution prevention specialists.

These options are presented so you can see what people in facilities are considering. As with any option (reviewed or unreviewed) you will have to adapt it to your facility.


No More Sand Absorbent

We replaced the sand absorbent that we used to pick up oil and brass grindings from the floor with absorbent socks. The process enable us to separate the oil from the brass grindings. The absorbent socks absorbed the oil and left behind the brass grindings. The brassgrinding were later pick up by wet mops where water and brass grinding were seperated by a chip removal system. The sock on the other hand is introduced to a compactor where oil is squeezed out for recycle and the socks are used again. The brass seperated from the mop water is also recycled as brass.

Food Products Manufacturing

Process raw materials such as soybean oil, starches, water, etc. into a finished product and package it for end user consumption

Process raw materials into a finished product

Process raw materials such as aluminum sheets into aircraft seat parts. Process some chemicals into seat parts. Metal is sheared drilled, milled, welded, riveted, painted, chromat conversion coated, adn the parts are assembly. Into a finished product.

Air Pollution Control Equipment

Use of SCR to reduce NOx emissions. Ammonia slip as a result of normal operations.

Produce Aluminum Die Castings

Melt aluminum ingots/clean scrap to be used by High Pressure Die Casting machines

Process Die Cast wastewater

collect die cast wastewater from die cast sumps and processing by evaporation

Process/remelt aluminum production scrap

Aluminum die casting scrap is returned to the furnace room for classification, sorting and disposition.

Reduce vibratory sludge waste

As vibratory cones wear they deposit ceramic clay mud in the wastewater stream

Process coils of steel into pipe

Steel coils are slit to width then formed into pipe. Electric Resistance Welding is used to seal the seam. If ordered by customer, pipe is grooved or coated.

Manufacture glass bottles

Optimize the manufacturing process and the batch mix to minimize toxic releases.

Pipe Threading and Manufacturing

Threading of Oil Country Tubular Goods and Coupling Manufacturing

Populate printed circuit boards

Use surface mount technology to produce populated PC boards.

Reduce volume of oily scrap

Reduction could be accomplished by providing catch screens to prevent scrap from reaching the waste oil and residue on the floor under the casting machine.

Reduce amount of molten aluminum spilled

Redesign pouring troughs to reduce spillage when recharging holding furnaces. Install funnels on all shot sleeves to prevent spillage. Provide catch pans under pouring troughs to catch spillage.

Shutdown & Exhaust System Installation

The water base plant, which generates liquid waste was shutdown in September 2002, eliminating totally its waste. For the Vynil Acetate, an exhaust system will be installed to decrease the emmision,

Control system review

review large energy users in the plant and install computerized sequencers and controllers to limit energy use to a minimum.

Neutralize Acidic Waste

Neutralize acidic waste leaving plant from sanitizing process to make non-hazardous non-toxic waste

Process coils of rod into wire

Coils are cleaned through the use of 12% sulfuric acid then ran through a series of dies to create wire.

Process coils of rod into wire

Rod coils are immersed in a solution of 12% sulfuric acid for cleaning. The rod is rinsed & coated then sent through a series of dies to reduce the rod into wire.

Process Change

Increasing the size of the quartz wafer used in the manufacturing process.

Manufacture Hot Mix Asphalt

Collect dry aggregate into bins, come together in fired rotary drum where liquid asphalt is introduced.

Alternate Solvent

Use a low vapor pressure solvent

Alternate Raw Material

Use a low vapor pressure raw material.

Footwear Manufacturing

Manufacturing of footwear; Cutting material, assembling, finishing and packaging.

Reduction of Solvent Waste Production

Reduce the amount of solvent waste by segregation, recycling, and reuse.

Process Manufacturing - Alkylation Wash Section

Alkylation wash section using dilute caustic to wash crude alkylate to remove unreacted catalyst and neutralize the in process stream.


Recycle wood pallets and boxes by reuse or chipping for ground cover.

Insulating and Marking of Copper Wire

Marking the insulation of the wire uses inks and solvents. the waste ink and solvent is recycled and the solids thrown away. the recycle material is used for cleaning of the marker parts.

Draw down Copper Rod to Wire

using pulling capstans and cutting fluid, copper rod is drawn down in size, cutting fluid is removed as oily waste.

Recycling of flux

Flux used in the process is now recycled, virtually eliminating this waste stream.
Find Options for other processes

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