Mr. M Billinghurst Fuji Graphic Systems Canada Inc. 6425 Airport Road Mississauga, ON L4V 1E4 Re: Metafix pH Neutralization Unit at "customer name withheld" Dear Murray: The testing of the Metafix pH Neutralization Unit installed on the Fuji computer to plate processing line at "customer name withheld" is now complete. The following report is specific to: The Fuji Luxcel 9600 Computer to Plate installation, processing the Fuji Digital Plate LPN3. The chemistry in this plate line is Fuji Digital Plate Developer, LPD3 and LPDR3. The testing protocol undertaken by Envision was designed to determine: The consistency of the neutralization unit and its components The acceptability of the resultant effluent for disposal in the sanitary sewer The practicality of using the neutralization unit with this equipment/plate/chemistry configuration Process comments The Fuji Luxcel 9600 Computer to Plate processor is designed to minimize energy and processing chemistry usage. Along with using very low chemistry replenishment rates, the Fuji Luxcel 9600 processor minimizes the amount of water used for processing. When combined with the chemistry formulation, the water minimization feature is environmentally preferable over previous water recirculation technology. The developer replenisher is added to the processor on a per plate basis as well as and on a per hour basis. When the chemistry is injected into the processor, a corresponding amount of used chemistry overflows into the neutralizer unit. The overflow chemistry is captured in an internal tank within the neutralizer unit. When a sufficient quantity is collected it is neutralized, and then discharged to the sanitary drain. To ensure consistent testing, it was necessary to use a consistent sampling time frame. To do this we captured the total amount of wastewater flowing to the sanitary sewer from the CtP and neutralizer for a one-minute period. The actual flow rate was measured at 20 Litres per minute. This became our sample period as it represented a complete batch cycle for the CtP neutralization unit/CtP combination. Installation of neutralization unit: The Metafix unit was installed on June 11. Operation of the neutralizer was in accordance with manufacturers specifications. The unit was adjusted to inject a sufficient amount of neutralizer into the reaction chamber to bring the pH of the effluent within the compliance limits of the sewer use bylaw. The initial pH test at the time of installation showed an effluent pH of 9.7. The unit was then considered to be ready for production and the sampling program set to begin. However, the processor/neutralizer configuration was not used for regular production until early July. Therefore the sampling program was delayed until July 13. Neutralizer unit testing: The sampling period ran from July 13th until September 24th. During the test period, the unit operated normally. It handled the effluent in a manner that met the requirements of the Toronto sewer use bylaw. The testing period included two occurrences when the contents of the processor tanks were transferred to the neutralization unit along with large amounts of water, during a processor maintenance event. The neutralizer unit continued to operate normally, and the effluent was within required parameters during both maintenance events. At the time each sample was taken the following items were checked and verified: Correct operation of the pumps Ratio of the neutralizer against the developer overflow Calibration of the pH probe within the Metafix unit Timing of the ejet evacuation step pH of the effluent being discharged Neutralizer unit operational consistency Over the time of the sample program, the staff at "customer name withheld" was asked for input on the operation of the neutralizer unit. All comments indicated that they did not have to intervene in the operation of the Metafix unit. The unit was considered to be 100% operational during the testing period. pH probe calibration At each sampling event, the accuracy of the internal pH probe was checked. It was found to agree with calibrated test equipment within an acceptable tolerance of +/- 0.2. The internal pH probe did not require re-calibration during the sampling program. Neutralizer effectiveness The neutralization unit was operated at different neutralizer to developer overflow ratios. During these tests, the pH results were predictable. TABLE 1 Date Total Neutralizer Total Litres pH Ratio 12-Jun 1 14 9.7 8.3 13-Jul 7 72 8.9 11.1 17-Jul 9 89 9.4 11.1 20-Jul 9 96 9.4 11.1 24-Jul 11 116 9.4 11.1 27-Jul 12 124 9.2 11.1 31-Jul 21 221 6.6* 11.1 3-Aug 29 321 6.1* 11.1 9-Aug 34 375 6.6* 11.1 17-Aug 40 443 9.4 11.1 24-Aug 45 497 9.5 11.1 31-Aug 55 608 9.6 11.1 24-Sep 90 991 8.9 11.1 * These pH results are within acceptable limits for disposal to the sanitary sewer in the City of Toronto. Please note the neutralizer unit handled large amounts of rinse water from maintenance operations. This was inadvertently directed to the neutralizer instead of the drain. These results are within expectations. Although no user intervention was required, the neutralization unit permits the user to raise or lower the pH as required by local regulations. Table 1 Definitions: Date - The date on which the samples of effluent were taken Total Neutralizer - The readout of the accumulative amount of neutralizer used to date. Total Litres - This represents a running total of the amount of effluent processed through the neutralizer unit pH - The pH number represents the pH reading of the neutralized effluent in the reaction chamber, prior to being discharged to the drain. Ratio - This figure represents the developer tank overflow to the neutralizer added to the reaction chamber to make one batch. The altering of this ratio provides the ability to raise or lower the pH of the effluent. Analytical commentary: Aluminum At the time of the equipment being first used for regular production, the aluminum content in the effluent was found to be 3 times the sewer use compliance limits. This was the first use of the Metafix unit with this process chemistry combination. Therefore a pump adjustment was made to configure the Metafix equipment for this specific process chemistry/plate combination. Subsequent analytical results confirmed the pump adjustment had brought the aluminum levels within compliance limits. Biological Oxygen Demand (BOD) With the exception of the total water flow tests; all samples were taken from the internal reaction chamber of the Metafix neutralization unit. During the final sampling the BOD was measured at 2 times the sewer use compliance limit. However when reaction chamber empties it combines with the process water prior to the entry to the sanitary sewer drain. The ratio is 1 part effluent from the reaction chamber to 10 parts process water. The resultant BOD concentration from the combined effluent streams will be within acceptable levels. Summation In our opinion, the effluent from the Fuji Luxcel 9600 CtP installed at "customer name withheld", is operating in compliance with the City of Toronto, sewer-use by-law #457-2000, following treatment through the Metafix pH Neutralization Unit. Sample analysis verified that the resultant pH following neutralization can be predicted, and controlled using recommended operating procedures. We also noted that the effluent from the CtP did not have a tendency to form a gel like substance. This property reduces the possibility of drain problems. Envision Compliance Ltd. T. A. Gorham Back to Metafix CTP pH Control