Ala. Admin. Code r. 335-3-6-.43

Current through Register Vol. 43, No. 1, October 31, 2024

Section 335-3-6-.43 - Graphic Arts

(1) For the purpose of this Rule, the following definitions apply:

(a) "Packaging Rotogravure Printing" means printing upon paper, paper board, metal foil, plastic film, and other substrates, which are, in subsequent operations, formed into containers and labels for articles to be sold.

(b) "Publication Rotogravure Printing" means printing upon paper which is subsequently formed into books, magazines, catalogues, brochures, directories, newspaper supplements, and other types of printed materials.

(c) "Flexographic Printing" means the application of words, designs and pictures to a substrate by means of a roll printing technique in which both the pattern to be applied is raised above the printing roll and the image carrier is made of rubber or other elastometric materials. The two roller inking system consists of an ink trough, a rubber covered fountain roller, and a screened (Anilox) inking roller with cells of uniform size and depth. The fountain roller transfers the ink from the trough to the anilox roller cells. The anilox roller may be engraved or etched metal or ceramic. The cells of the anilox roller transfer the inks to the surface of the flexographic plate.

(d) "Roll Printing" means the application of words, designs and pictures to a substrate usually by means of a series hard rubber or steel rolls each with only partial coverage.

(e) "Rotogravure Printing" means the application of words, designs and pictures to a substrate by means of a roll printing technique which involves an intaglio or recessed image areas in the form of cells.

(f) "Letterpress Printing" means the application of words, designs, or pictures to a substrate by means of a raised ink surface in the mirror image of the printed material or "wrong-reading". The ink is transferred to the substrate directly from the raised surface. Inking rollers transfer the ink from the ink trough directly to the image carrier. Letterpress inks, which typically have the consistency of paste, are viscous and tacky.

(2) This Rule shall apply to packaging rotogravure, printing rotogravure, and flexographic printing facilities.

(3) No owner or operator of a packaging rotogravure, printing rotogravure or flexographic printing facility subject to this Rule and employing solvent containing ink shall operate, cause, allow or permit the operation of the facility unless:

(a) the volatile fraction of ink, as it is applied to the substrate, contains twenty-five percent (25%) by volume or less of organic solvent and seventy-five percent (75%) by volume or more of water; or

(b) the facility prints with ink which contains sixty percent (60%) by volume or more nonvolatile material; or

(c) the owner or operator installs and operates:

1. a carbon adsorption system which reduces the volatile organic emissions from the capture system by at least ninety percent (90%) by weight; or

2. an incineration system which oxidizes at least ninety percent (90%) of the VOCs (VOC measured as total combustible carbon) to carbon dioxide and water; or

3. an alternative VOC emission reduction system demonstrated to have at least a ninety percent (90%) reduction efficiency, measured across the control system, that has been approved by the Director.

(4) A capture system shall be used in conjunction with the emission control systems in subparagraph (3)(c) of this Rule. The design and operation of a capture system must be consistent with good engineering practice, and shall be required to provide for an overall reduction in VOC emissions of at least:

(a) seventy-five percent (75%) where a publication rotogravure process is employed;

(b) sixty-five percent (65%) where a packaging rotogravure process is employed; or

(c) sixty percent (60%) where a flexographic printing process is employed.

(5) If add-on control equipment is used, continuous monitors of the following parameters shall be installed, periodically calibrated, and operated at all times that the associated control equipment is operating:

(a) exhaust gas temperature of all incinerators;

(b) temperature rise across a catalytic incinerator bed;

(c) breakthrough of VOC on a carbon adsorption unit; and

(d) any other continuous monitoring or recording device required by the Director.

(6) The owner or operator of all Graphic Arts sources subject to the requirements in this Rule shall maintain as a minimum the following records to demonstrate compliance in the time frame required by any regulation under this Rule or Air Permit condition:

(a) The quantity in gallons of all inks delivered to the application system; and

(b) The quantity in gallons of all organic liquid dilutents (ink thinners and additives) added to the surface coatings; and,

(c) The quantity in gallons of all organic liquid solvents used for wash (blanket) or cleanup; and,

(d) The quantity in gallons of all organic liquid waste properly contained and shipped out for proper disposal and a certification of the waste density and percent VOC content by weight; and,

(e) The following information on all inks and organic liquid solvents (dilutents, wash, and cleanup):

1. Manufacturer; and,

2. Product name and manufacturer's code number; and,

3. Density (pounds per gallon); and,

4. VOC content in percent weight and volume; and,

5. Solids content in percent weight and volume; and,

6. Water content in percent weight and volume; and,

7. Exempt VOC content in percent weight and volume.

(f) The permanent records required under this paragraph shall be retained by the owner or operator at the location of the regulated source for a minimum of two years after the date of record and shall be available to representatives of the Director upon request.

(g) The recordkeeping provisions of this paragraph 335-3-6-.43(6) shall not apply if the Director determines that alternative records would be sufficient to provide assurance that the source is operating in compliance on a twenty-four (24) hour basis and these alternative requirements are incorporated as permit conditions for the source. In no case can recordkeeping requirements be waived or the stringency of the emissions limit be relaxed.

Author:

Ala. Admin. Code r. 335-3-6-.43

Effective Date: June 9, 1987. Amended: Effective Date: July 31, 1991. Amended: Filed October 17, 1996; effective November 21, 1996.

Statutory Authority:Code of Ala. 1975, §§ 22-28-14, 22-22A-5, 22-22A-6, 22-22A-8.