In 1994, 16 facilities with SIC Code 22 ("TextileMill Products") submitted a New Jersey Release and Pollution Prevention Report to the NJDEP describing their use of hazardous chemicals in 1993. Since plants with SIC Code 22 are considered Group Two facilities by the NJDEP, they must prepare a Pollution Prevention Plan and submit a Pollution Prevention Plan Summary by July 1, 1996. As part of the preparation of a Pollution Prevention Plan, facilities are asked to find and analyze pollution prevention options and set reduction goals for hazardous chemical nonproduct output (NPO) and use.

The following pages list some pollution prevention techniques compiled by the United States Environmental Protection Agency (USEPA) that SIC Code 22 facilities may find useful to help set (and eventually meet) hazardous chemical NPO and use reduction goals.

The primary focus for achieving pollution prevention in textiles manufacturing is on reductions in water, chemicals, energy use and the utilization of less hazardous, more efficient, and more recoverable compounds through material substitutions, process changes, and reuse strategies.

Material change strategies have focused on decreased toxicity, increased recoverability and improved efficiency of reactions. One example of eliminating hazardous materials is using Epson salts as an antimigrant until the fixative can be applied from a continuous resin finish formulation to avoid both heavy metals and biochemical oxygen demand (BOD).

Process change methods include advanced dye bath techniques for aqueous processing, alternative application media and delivery, and improved washing efficiency. In addition, overall strategies such as combining individual process steps into one step offer a more systematic and holistic approach to minimizing waste. A key to accomplishing dyeing procedures is to have accurate dispensing systems which will meter given amounts of dyes and chemicals and feed them into machines at predetermined programmable rates.

For example, in fiber reactive dyeing, alkali added all at one time will produce a rapid exhaust of dye onto the fabric and reaction. Alkali, if added in small discrete quantities, will produce a series of rapid strikes of dyes onto the fabric. A continual and controlled addition of alkali can cause a smooth and even exhaustion of dye onto the fabric.

Some pollution prevention tips:

• Make sure hoses are not left running.
• Replace broken or missing valves.
• Don't leave cooling water running when machinery is shut down.
• Replace defective toilets and water coolers.
• Reuse noncontact cooling water by sending it back to a clear well or influent water line to the mill.
• Use countercurrent washing techniques.
• Practice rapid inverse dyeing (RID).
• Remove water from waste liquids with a water evaporator, (a hot evaporation system) which is a natural gas fired, air assisted evaporator for the removal of water from waste liquids. The purpose of the unit is to safely concentrate and contain hazardous waste liquids.
• Look for marketability in waste products. For example, waste print paste has significant potential for improved market value as a concrete additive for colored concrete.
• Consider speaking to liaisons available for materials exchange between generator and potential users of the wastes. The materials exchange may analyze and treat the waste to make it a suitable raw material for buyers to use. The type of exchange actively seeks buyers for the wastes.
• Eliminate phosphates wherever possible.
• Explore solvent processing techniques.
• Use bathless washers.
• Use liquid-ammonia mercerization instead of caustic.
• Replace all chromates used for oxidation of vat dyes.
• Evaluate all maintenance chemicals for metals and toxicity.
• Save energy by removing water by centrifugal means, rather than evaporation.