Toxics Use Reduction Institute TURA and Tech Diffusion in the Plating and Food Industry Buenos Aires September 31, 2009 Janet Clark, Senior Associate Director

Toxics Use Reduction Act Goals Reduction in use of toxic chemicals and generation of wastes – source reduction Establish TUR as the preferred means of regulatory compliance Sustain and promote the competitive position of Massachusetts industry Enhance and coordinate state agency enforcement of environmental laws

Progress TUR -- 40% Emissions Reduction -- 91% TUR Planning –70% of firms identified TUR options Implementation –81 % of the firms that identified TUR options in their plans reported implementing at least some of them –67% of firms reported cost savings –66% of firms reported health and safety benefits Materials accounting was rated the most valuable component of TUR planning 4

Fees Pay for TURI Services How to Design effective services for industry? Technology Diffusion Tools can help agencies TUR Planning is the best practice for industry TURI Laboratory is unique and effective

Technology Diffusion Everett Rogers classic model of diffusion of technological innovation (Rogers, 1995) “Diffusion is the process by which an innovation is communicated through certain channels over time among members of a social system” 1.Show economic or social advantage 2.Help connect the concept to values, beliefs, experiences 3.Address Complexity 4.Make it easy to do small scale testing 5.Offer demonstrations 6.Remove barriers ($, research, training)

Toxics Issues are Complex

Core Technology to Advance -- TUR Planning Companies with skills in planning and evaluating innovations will be more effective than promoting a particular innovation.

Process Characterization Process Characterization Pre-Plan Identify TUR Options Identify TUR Options Develop or Update Plan Develop or Update Plan Certify Plan Screen & Evaluate TUR Options Screen & Evaluate TUR Options Implement Plan TUR Planning Cycle Measure Success Green boxes are what TUR Planners do

Definition of TUR TUR Techniques: Improve processes Reformulate Substitute a safer material Redesign process, product, or service Improve operations and maintenance In-process recycling Reduce use of toxic chemicals or generation of waste at the source by using…

Technology Diffusion of TUR Difficult to advance because they are about “prevention”; market opportunities are easier Drivers of change play key role Regulatory: bans, phase outs, emission or use restrictions, fees Market: Customer “green” goals and brand protection, labeling, government Environmentally Preferable Purchasing (EPP) programs

Change Agents Change agents play a crucial role Technical assistance programs Must be funded! Researchers and universities Must be funded! Consultants to industry Must prove their value! Opinion leaders in industry Must be recruited

Identify Issue or Need Develop or Identify Innovative Solutions or Materials or Technologies Assess Alternatives Identify and work with Supply Chain Identify Industry Leaders Prove & Demonstrate Technology/Materials Provide Assistance: Testing, information, workshops, more R&D at Companies and Universities, on-site assistance, grants At a “critical mass” number of companies, adoption becomes self-sustaining Continuous Improvement

TURA Industry Programs 1.On-site Technical Assistance 2.University Research on Technical Problems (Grant program) 3.University Laboratory Testing Program 4.Technology specific Workshops and Seminars 5.Training and Conferences for TUR Planners 6.Peer Mentoring and collaboration

TUR Planning Example - Electroplating

TUR Planning: Options Identification and Evaluation Evaluate Screen Identify Evaluate remaining TUR Options T echnical evaluation Economic evaluation Brainstorm TUR Options Consider techniques Generate lots of ideas Eliminate TUR Options Technically or economically infeasible Not TUR For each toxic in each production unit,

TUR Planning: Cost Categories

Lightolier Changes Increased drip time to allow acids to return to chemical baths Installed still-rinse tanks used countercurrent rinsing. Looked at hidden costs of using TCE Switched from petroleum coolants to a water soluble formula Replaced an old vapor degreaser and reduced use of TCE by 98% (from 125,000 pounds per year) Switched to a brightner with 90% less copper to protect local wastewater treatment facility Attended program workshops Visited by OTA

Doing Planning Alternatives After several cycles of TUR planning, firms can choose to report on –Resource Conservation Planning – energy, water, materials –Integrating TUR Planning into Environmental Management Systems (EMS)

Lightolier 44 Million Gallons per Year Reduction $ 181,715 per year annualized savings

    Inner Tite Lightolier VH Blackington Olympic Mnf     97% reduction of TCE Zero Discharge to air 98 % reuse of plating chemicals $12,000 saved annually 1.2 million pounds TCE eliminated $2,000,000 saved Eliminated TCE 85% reduction in Copper and Zinc 95% reduction in Cyanide 75% reduction in coolant $38,000 saved annually TURA     { { { {

Many Successful Stories Tri-Star Technologies of Lowell produces printed wiring boards TUR planning identified the option of installing a electrolytic regeneration system to the cupric etch line, resulting in: –fully eliminating the use of hydrogen peroxide –a 90% reduction in the use of hydrochloric acid –recovery of 42,000 pounds of copper each year –a two-year pay-back of the $110,000 investment for the regeneration unit

Continuing Education Examples Innovative Coating Techniques National and Int’l Policy Organizational change workshops Toxicology Integrating Lean & Clean Manufacturing Industrial Energy Efficiency2 Green Chemistry Theory and Practice

Research and Technical Support –Research: collaboration through Industry Supply Chains (lead-free electronics) –Research: Applied Green Chemistry, Biomaterials, Nano-materials –Workgroup: Environmental Management Systems Peers –TURI Laboratory

TURI Laboratory

Pilot Cleaning in Lab Setting –Using client specific operating conditions –Using client supplied parts –Compare with current solvent (if possible) –Client assessment of results to confirm

Alternatives to TCE

TURI Laboratory Assists industry and communities in the search for safer cleaning processes –Tests the performance of alternatives to hazardous solvents –Extensive database of results at Janitorial cleaning Industrial parts cleaning TCE Cleaning Use Data

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