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Case Summaries written by:2008 P2 InternsSpecial Thanks to:Danielle DilksJeff FiagleChuck GeguzisHeather JacobsStevie JohnsonLinda KingShelly PetersonJennifer ReutzelAllan GoldbergLayout by:Kati BainterIowa Pollution Prevention ServicesIowa Department of Natural Resources502 East Ninth StreetDes Moines, Iowa 50319-0034www.iowap2services.comPhone: (515) 281-5353Fax: (515) 281-8895Director:Richard A. LeopoldEnvironmental ServicesDivision Administrator:Wayne Gieselmanland qualityBureau Chief:Brian Tormey

2008Pollutionpreventioninterns Contents67Director’s Notes83M Knoxville10Acument Global Technology12American Packaging Corporation14Burke Corporation16Clow Valve Company18E.I. DuPont20Frontier Natural Products Co-op22GE Consumer and Industrial24Global Ethanol26Hearth & Home Technologies, Inc.28Hy-Vee Inc.30Jennie Edmundson Hospital32John Deere Engine Works34John Deere Ottumwa Works36Kraft Foods Global, Inc.38Mercy Hospital40Siegwerk USA Co.42Hospitals for a Healthy Environment Circuit Rider44Pollution Prevention Services46GELITA USA Inc. (2007 Six-Month internship)48502008 Project indexExecutive SummaryIntern: Heath VignesIntern: Phillip MannIntern: Jared NoackIntern: Sara SchmeigIntern: Eric OstranderIntern: Ryan WendtIntern: Trent PayneIntern: Jesse ShuckIntern: Robert GippleIntern: Scott SalsberyIntern: Andrea SiefersIntern: Steven NelsonIntern: Carmi SpicerIntern: Zachary RodenbergIntern: Tim HillIntern: Andrew PatzIntern: Adam Beranek-CollinsIntern: Brett EdwardsIntern: Jessica Heth, Eric NevermanIntern: Anne GraberApplication process

Director’s NOte2008 Executive Summary2008 was a year of outstanding accomplishments forthe award-winning Pollution Prevention Intern Program.These are challenging times for Iowa businesses. Energy andresource costs are skyrocketing. At the same time, consumers arefavoring products produced by responsible environmental stewards.For Iowa businesses to maintain a competitive edge and growin an increasingly competitive global market, they will have to recognizethese challenges as opportunities — opportunities to incorporate resourcemanagement practices that lower their input costs and the opportunity toreduce their environmental footprint.This year, 21 interns implemented projects thatdramatically reduced solid and hazardous waste, waterand energy use, air emissions, and greenhouse gases.The projects this year saved participating companiesand institutions over 1.5 million dollars. Since theprogram’s inception in 2001 Iowa businesses havesaved more than 54.3 million dollars.Eight years ago, the Iowa Department of Natural Resources developedthe Pollution Prevention Intern Program as a collaborative effort betweengovernment, business, and academia to develop cost-effective options forpreventing or minimizing pollution from industrial processes. The programhas been a phenomenal success. By placing qualified Iowa college studentswith Iowa companies to identify, research, and implement changes thatresult in environmental and financial savings, everyone wins.The program’s unique partnership of government,academia, and industry make these achievementspossible. With the Iowa Department of NaturalResources’ (DNR) support, top Iowa students sharetheir talent, hard work and fresh perspectives withcompanies and institutions dedicated to environmentalexcellence. In return, the students gain valuable trainingfrom experts in their fields and hands-on professionalexperience. All Iowans benefit from the lastingenvironmental impacts this partnership creates.In 2007, I established a Top 10 Priorities list as a means for identifying our top environmental priorities and actingon them. Pollution prevention is at the core of these priorities, and programs like the Pollution Prevention InternProgram help us act on those priorities practically across the board. Pollution Prevention Intern projects improve theway Iowa businesses manufacture, consume, reuse, and recycle materials. They also conserve water, improve waterquality, improve air quality, and reduce greenhouse gas emissions to the atmosphere.As the Pollution Prevention Intern Program evolves, theDNR continuously strives to improve our services. Tothat end, two of the 2008 interns performed on-siteassessments at previous host companies and institutions.The interns followed up on project recommendationsthat had been made by past interns, and thecompanies and institutions generously shared theirinsights about the program’s results and effectiveness.These assessments helped us to better understandcompany priorities, barriers to implementation, andenvironmentally sustainable trends. The evaluationsstrengthened our existing partnerships and will beextremely valuable as we gear up for future projects.Typically, after one week of training, interns spend 11weeks at the host facility. This year, two of our 2008interns are undertaking 24-week projects, at Proctorand Gamble in Iowa City and West Liberty Foods inWest Liberty, Iowa. After these projects are completedin November 2008, their summaries will be availableonline, at We will alsoinclude these projects in our 2009 case summarybooklet.The DNR thanks 2008’s host companies and institutionsfor their leadership, vision, and environmentalstewardship, and we commend the interns for tacklingthe important challenges summarized in this booklet.Since 2001, the implementation of Pollution Prevention Intern recommendations has saved over 1 billion gallons ofwater, 108,947 tons of solid waste, 942,332 gallons of hazardous waste, 100,601 tons of special waste, and over221.5 million kilowatt hours and 2.29 million therms of electricity.One of the concepts Pollution Prevention Interns are encouraged to practice is to look for continuous processimprovements. During the summer of 2008, program administrators decided to use that concept to examinethe Pollution Prevention Intern Program itself. Two former interns were hired to audit the program to see whereimprovements can be made and to identify opportunities for the future. With the goal of continuous improvementin mind, the interns’ recommendations are being reviewed, and process improvements to the program will beimplemented and made available for future interns to carry forward.I encourage you to read the case studies and student testimonials that follow. You, too, can partner with the IowaDNR by applying for our summer of 2009 Pollution Prevention Intern Program.Air Emissions Avoided in TonsCategory Cost SavingsWater conservation12,887,600 gallons 101,706Solid waste581 tons 119,561Hazardous waste95,850 gallons 587,307Energy4,263,029 kwh479,317 therms 247,699 471,636totalRichard A. LeopoldReduction 1,527,909Note: Air emissions and greenhouse gases shown in the following case summaries are Life Cycleestimates and include external activities such as purchasing utilities. Totals do not solely representemissions generated at the plant sites.Total for all .1018Green House Gases Divertedin Tons (CO2 Equivalent)Total for all 4

3M Knoxvilleflow of hot air to the waste heat boiler. This, however,was determined to be infeasible since it would cost theplant a substantial sum of money and natural gas toproduce steam in this manner.Company BackgroundThe 3M plant in Knoxville, Iowa specializes in creatingpressure sensitive tapes and adhesives. The majority ofthese tapes and adhesives are developed on a custombasis to meet the demands of the individual customer.The applications of these tapesrange across many industries, from K no x villeattaching parts in the automotiveindustry, to tape for use in diapers,to the fasteners used to hold upthe mirrors in the walkways ofChicago O’Hare Airport.the summer months and supplement the 60,000-poundboilers in the winter enough so that only one would needto be turned on.Because this option was not practical, the finalrecommendation was to install a 25,000-pound wasteheat boiler with its own fuel line. This would allowfor fluctuations in the amount of hot air bypass. Theinstallation of a waste heat boiler would allow the plantto turn off both of its 60,000-pound boilers duringIt was also determined that the efficiency of theregenerative thermal oxidizer should be increased from90 percent to 95 percent to gain even more energyfrom the waste heat. To do this, an additional 18 inchesof ceramic media should be added to the regenerativethermal oxidizer, which should increase the efficiency to95 percent.Air Pollutants Diverted in TonsTotal for all sectorsHeath VignesMechanical EngineeringUniversity of IowaProject BackgroundThe project at 3M Knoxville consistedof recapturing heat from theirregenerative thermal oxidizer with awaste heat boiler. The process wouldthen provide the plant with “free” steam during thesummer months and supplemental steam for their boilerduring the winter months, when the plant requires moresteam for its heating and processes.Incentives to Change3M Knoxville undertook the opportunity to partner withthe IDNR Pollution Prevention Intern Program based onthe desire to cut costs at their plant. The reduction ofpollutants was an added bonus since they were alreadywell under their allowed permits for pollution. The need to cut energy costs was their main motivation with the risingprices of natural gas and oil. 3M Knoxville is currentlyexperiencing the highest prices they have ever paid fornatural gas and the prices are only expected to increasewith the onset of winter.0.818CO1.51NOX0.875VOC1.86PM0.081Green House Gases Divertedin Tons (CO2 Equivalent)ResultsWaste Heat Boiler: 3M Knoxville’s regenerative thermaloxidizer produces exhaust air of 850 F to 1500 F to theatmosphere. The goal was to determine the most efficientmethod to recapture this heat and put it to a constructiveuse for the company. It was determined that the bestoption for effectively recovering this heat was to install awaste heat boiler to the hot air by-pass that comes off ofthe regenerative thermal oxidizer.The regenerative thermal oxidizer does not consistentlyproduce enough hot air that the hot air by-pass iscontinuously in use. Initially it was thought that it mightbe cost-effective to simply over-fire the burners in theregenerative thermal oxidizer to maintain a consistentSO2Total for all sectorsprojectWaste Heat BoilerCO22519CH4482N2O1.22CFCS3.67Annual CostSavingsEnvironmentalResultsStatus 317,172.91264,310 ThermsRecommended

Acument GlobalTechnologYCompany BackgroundWaste Heat Recovery: In the heat treating sectionat Acument, two furnaces and several other heatersexhaust an immense amount of heat through the roof.To conserve on energy and to recover the otherwiselost heat, a waste heat generator was investigated.Acument’s exhaust qualifies it for a 50 kWh wasteheat generator that would allow it to produce partof its own energy with a rate of return of about twoyears. If the project works at the Decorah Acumentsite, other sites with heat treat will begin their ownwaste heat projectsAcument Global Technologies is an internationallyaccomplished competitor in the mechanical fasteningand assembly solution industry. Serving more than150 countries, Acument’s net sales exceed 1.8billion. Acument adheres to a continuous improvementprogram and a Lean Manufacturing process tocontinue to ensure the growth of the company. AcumentDecorah Operations’ customers include a largetelecommunications companyD ecorahand major vehicle and toolsmanufacturers. Currentprocesses at Acument DecorahOperations include heading,threading, shaving, grinding,heat treating, and painting.Phillip MannMechanical EngineeringIowa State UniversityProject BackgroundAcument Decorah Operations hashosted Pollution Prevention Programinterns for five summers, and isinterested in continuing the success ithas experienced with the program. Each intern decreasesthe environmental footprint of Acument and providesannual cost savings. This year, the Decorah plant isfocusing on waste heat reclamation and soap/water reuse.Incentives to ChangeWith rising prices of gas and water, environmental projectsbecome even more important for sustainability and thegrowth of the company. Reduction at the source can beoverlooked, as it is often not readily apparent. Locatingthese sources and finding feasible alternatives or solutionsto implement will provide the host company with largeannual savings.10Wastewater Recovery: Under the current wastewatertreatment system, a large amount of wastewater is sent todrain, treated or hauled off-site. Some water is merely usedto cool or heat and then sent to drain without any sort ofcontamination or recycling. To cut down on the water useand treatment costs, a wastewater recovery system wasrecommended. The new system uses a reverse osmosis,hydrophilic cycle to distill and recover 95 percent to 98percent of all water used. Not only does this drastically cutdown on water consumption, but also on treatment andhauling costs.Air Pollutants Diverted in TonsTotal for all sectors3.917CO0.468NOX1.876VOC0.23PM0.099Green House Gases Divertedin Tons (CO2 Equivalent)ResultsWash Treatment Systems: Most parts must pass througha wash treatment before they are packed. A majority ofthe parts wash machines were over-specified for the ratedtemperature for the type of soap they were using. Testingto find the most efficient temperature on these machinesdetermined the natural gas and electricity that could besaved by operating closer to specifications. In addition,several machines had an excess concentration of soap.Using proportioners and cutting down on overuse will saveAcument money on soap purchases and on wastewatertreatment costs.Soap Analysis: The soap currently used for the washprocesses is a basic, inexpensive heavy-duty cleaner.Several tests were conducted to determine if more advancedor different soaps could perform better. Testing showed thatlow-temperature cleaners were appealing but not capableof the cleaning power of the current soap. However, adifferent alkaline soap showed positive results in cleaningbetter than the current soap at lower concentrations.This cleaner costs less and can be operated at lowerconcentrations to save on wastewater treatment as well.SO2Total for all sectorsCO2734.03CH464.78N2O0.347CFCS9.0Annual CostSavingsEnvironmentalResultsStatusWash Treatment Systems 62,8004,350 Gal soap2362 CCF Natural Gas61,800 kWhimplementedSoap Analysis 11,0001500 Gallons soapprojectImplementationin Progress,Testing ContinuesWaste Heat Recovery 39,900420,000 kWhin progressWastewater Recovery 24,160 8,701,880 GallonsRecommended11

AmericanPackagingCorporationCompany Backgroundlighting layouts and fixtures around the facility, whichincreased the electric bill. Re-lighting the facilitywith new T5 high output fluorescents will improvethe lighting efficiency and provide a safer workingenvironment. The new fluorescent lights will provide amore efficient lumen output. Placing occupancy sensorsin the warehouse and in other infrequent traffic areaswill reduce their kilowatt-hour usage. The EPACT taxcredit of 2005 will help American Packaging reduce theinstallation cost of re-lighting the plant area.American Packaging Corporation is a flexible packagingmanufacturer servicing food, beverage, medical, personalcare, household, pet food, agricultural chemical, and lawnand garden markets. American Packaging Corporationemploys over 550 people and is one of the largest privatelyheld packaging companies in the world. Its operations includerotogravure and flexographic printing, adhesive and extrusionlaminating, hot and cold seal coating, pouching, and bagging.The Story City facility has 130employees and produces intermediatestor y cit yand wide webbing using 2- to 3-plyadhesives lamination. They operatethe latest slitting and rewindingequipment and have the ability tomanufacture bags and pouches with awide range of structures.Fixture Diversion: A local company with a morefeasible application for metal halide fixtures has beencontacted. The company will take the fixtures free ofcharge, thereby diverting 4.5 tons of solid waste fromthe landfill and saving disposal fees.Mechanical EngineeringIowa State UniversityProject BackgroundAmerican Packaging Corporation hasimplemented sustainable practicesfor the past decade. This summer thecompany partnered with the PollutionPrevention Program to help make progress on stalledprojects as well as to identify and implement new projectsto reduce the amount of energy consumed.Incentives to ChangeAmerican Packaging Corporation has divisionalpackaging “green team” members. Their goal is to helpAmerican Packaging become green and sustainable.In order for American Packaging to stay competitive, itmust meet the demands of their customers, who are alsotransitioning to sustainable practices. That is why they are12Air Pollutants Diverted in TonsTotal for all sectorsBoiler: A boiler replacement project would have anumber of beneficial environmental impacts. The boilermaking great strides towards recycling every piece oftheir solid waste, and are looking for ways to reduceelectricity, water, and gas consumption, as well as toreduce solid and hazardous waste.ResultsCompressed Air: Every machine in the plant dependson and uses compressed air. The demand for airaccounts for 16 percent of the electric bill. A leakdetection program was implemented and 122 leakswere found. A repair program was implemented tofix all leaks. Continuing the leak detection and repairprogram will help reduce costs. A leak reportingprogram was introduced to the machine andmaintenance workers to help them identify and repairthe noticeable leaks.Lighting: A lighting audit was done, revealing that thelighting conditions around the plant could be improved.The lighting conditions were impaired by inefficientGreen House Gases Divertedin Tons (CO2 Equivalent)Total for all 564VOC0.2167N2O33.51590.0891CFCS7.8936PMAnnual CostSavingsEnvironmentalResultsStatusRepair Compressed Air Leaks 26,339376,270 kWhImplementingRe-Lighting 24,593367,585 kWhImplementingRe-Lighting 2,892611 thermsImplementingFixture Diversion 1,2844.5 TonsImplementingEliminate Boiler 1,31719,551 kWhRecommended 10,99225,550 GallonsRecommendedEliminate Boiler - Chemical 1,04111 GallonsRecommendedEliminate Boiler 14,73921,168 ThermsRecommendedInsulate Boiler 3,1703,762 ThermsRecommendedprojectJared Noackis currently used for the drying process on one printingpress. The process takes place more than 200 feet fromwhere the boiler is located. Replacing the boiler with adirect gas-fired heat exchanger will save great quantitiesof water, chemicals, natural gas, and maintenancelabor. The boiler itself emits temperatures of 250degrees Fahrenheit. If the boiler is not replaced in thenear future, insulation is recommended for both safetyand energy conservation purposes.Eliminate Boiler - Water13

BurkeCorporationCompany BackgroundGrease Recovery: Through process changes, as well asinstalling catch pans, an additional 242,000 pounds ofgrease can be recovered a year. Recovering additionalgrease during sanitation not only reduces treatment costs,but also increases grease revenue.Burke Corporation, a subsidiary of Hormel Foods,manufactures and markets fully cooked meat productsfor businesses that include restaurant chains andconvenience stores. Burke makes more than 1,500different products and processes over 80 millionpounds of meat a year. Burke makes consistent,convenient and safe products, witha forty-year history and commitmentnevadato service, quality and productdevelopment. Hormel Foodspurchased Burke Corporationin 2007 and has continued thededication to consistent, convenientand safe products.Sara SchmiegEnvironmental EngineeringIowa State UniversityProject BackgroundBurke Corporation has consistent

6 hearth & home techNoloGies, iNc. Intern: Scott Salsbery 8 hy-vee iNc. Intern: Andrea Siefers 0 JeNNie eDmuNDsoN hosPital Intern: Steven Nelson JohN Deere eNGiNe worKs Intern: Carmi Spicer 4 JohN Deere ottumwa worKs Intern: Zachary Rodenberg 6 KraFt FooDs Global, iNc. Intern: Tim Hill 8

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