Skip to main content

Create an editable spreadsheet with the information indicated below. Each step in your calculations needs to be clear and easy to follow.

Facility information

Provide the facility information listed on the Calculating emissions page. In addition, include the following:

Describe the type of printing operation, such as non-heatset web, heatset web, flexographic, sheetfed lithographic, gravure, screen, or other.

List each substance — ink, thinning solvent, cleaning solvent, and fountain solution, etc. — that could reasonably be used in your operation. Use an abbreviation or code number for each material, if needed. Provide the following for each substance:

  • Density in lb/gallon, found on the material safety data sheet (MSDS) or safety data sheet (SDS)
  • VOC content in lbs/gallon, found on the MSDS, SDS, VOC data sheet, or by contacting the manufacturer. If the document gives a range (e.g., 1-5%), use the highest number in the range. If the document gives VOC content in weight percent or volume percent, calculate the pounds per gallon:
    • VOC content (lb/gal) = VOC content (weight %) x substance density (lb/gal)
    • VOC content (lb/gal) = [VOC content (volume %) ÷ 100] x VOC density (lb/gal)
  • HAPs content (lb/gal) of each individual HAP and total HAPs, found on the MSDS/SDS or by contacting the manufacturer. If the document gives a range (e.g., 1-5%), use the highest number in the range. If the document gives HAP content in weight percent, calculate the pounds per gallon:
    • HAP content (lb/gal) = HAP content (weight %) x substance density (lb/gal)
  • For blanket wash and cleaning solvents, provide the vapor pressure in mmHg at 20 °C.

Include all relevant supporting documents with your application.

Example format for substance information

Substance Density (lb/gal) VOC Content (lb/gal) Solid Content (lb/gal) Total HAPs Content (lb/gal) HAP 1 Content (lb/gal) HAP 2 Content (lb/gal) Continue for each HAP
Ink A              
Ink B              
Fountain solution A              


Emissions calculations

As discussed on the Calculating emissions page, you will list the pollutants your facility emits in the left column, and each calculation will be another column in your spreadsheet. Provide the formula or equation for each calculation.

Calculate the maximum uncontrolled emissions in both pounds per hour and tons per year as described on the Calculating emissions page with some adjustments.

  • For fountain solution use: Determine your maximum possible usage of fountain solution in gallons per day based on historical records or records from a similar press. Make sure to adjust historical records to reflect the maximum capacity of your press.
  • For cleaning solution use: Determine your maximum possible usage of cleaning solution in gallons per day based on historical records or records from a similar press. Make sure to adjust historical records to reflect the maximum production capacity. Attached sheets showing your calculations.
  • For printing inks: Calculate the uncontrolled emission rate (lb/hr) for VOCs, each individual HAP, and total HAPs from ink use. Any physical limitations (i.e., dryer capacity) in the process may be used in your calculation, but they must be clearly supported. To find maximum ink coverage, use manufacturer's information, historical records, or data from a similar press. Retention factor in web for VOCs is generally 95% for non-heatset lithographic presses and 20% for heatset web lithographic presses. Retention is assumed to be 0% for all other types of printing. VOC/HAP content of the ink is based on the highest content for all inks. If Ink A has the highest VOC content and Ink B has the highest total HAPs content, use the value from Ink A for VOC emissions and the value from Ink B for total HAPs emissions.
    • For web presses: Potential emissions (lb/hr) = Maximum web speed (ft/min) x Maximum web width (ft) x Maximum ink coverage (lbs ink/ft2) x Maximum VOC or HAP content of the ink (lb/gal) ÷ ink density (lb ink/gal) x 60 (min/hour) x {1 – [Retention factor in web ÷ 100]}
    • For sheet-fed presses: Potential emissions (lb/hr) = Maximum press speed (sheets/hr) x Maximum sheet area (ft2) x Maximum ink coverage (lbs ink/ft2) x Maximum VOC content of the ink (lb VOC/lb ink) x {1 – [Retention factor ÷ 100]}
  • Calculate the maximum uncontrolled emissions:
    • Maximum uncontrolled emissions (tons/year) = Emission rate (lb/hr) x 8760 (hours/year) x [1 ton ÷ 2000 lb]
  • Include the pollution control efficiency percentage, which is the capture efficiency percentage multiplied by the destruction/collection efficiency percentage (shown on Form GI-05A or similar), for each pollutant. Form CD-05 also requires a plan to demonstrate and maintain the destruction/collection efficiency. If there is no control for a particular pollutant, indicate “zero” as the control efficiency.
  • Find the maximum controlled emissions rate:
    • Maximum controlled emissions rate (lb/hr) = Emission rate [lb/hr] x {[100 - Pollution control efficiency] ÷100}
  • Calculate the maximum controlled emissions:
    • Max. controlled emissions (tons/year) = Max. uncontrolled emissions [tons/year] x {[100 - Pollution control efficiency] ÷100}
  • Include the maximum hourly emission rate allowed under 40 CFR pt. 60, 40 CFR pt. 61, 40 CFR pt. 63, or Minn. R. ch. 7011. See form GI-09 for applicable regulations.
  • Find the limited controlled emissions (tons/year) by taking into account all your facility's operation limits, such as hours of operation, amount of material handled, etc. Repeat the emission rate calculation by multiplying the emission factor by the maximum capacity of the operation, but take into account your operation limits. If an emission unit is subject to an emission limitation specified in 40 CFR pt. 60, 40 CFR pt. 61, 40 CFR pt. 63, or Minn. R. ch. 7011 or you are proposing a more stringent limit, you must indicate this and include those factors in the calculation.

Actual emissions

Calculate actual uncontrolled emissions – calculate this as described on the Calculating emissions page with some adjustments:

  • For heatset equipment: In addition to the retention rate assumption discussed earlier, you may also assume:
    • 100% carryover of VOCs from ink to the dryer, which means that all VOCs are emitted from the dryer rather than the press.
    • 70% of the VOCs emitted from fountain solution occur at the dryer, and 30% at the press, if there are alcohol substitutes in your fountain solution.
    • 40% of the VOCs from blanket wash occur at the dryer and 60% at the press, if you operate an automatic blanket wash system where the vapor pressure is 10 mmHg or less at 20 °C.
  • Assume that 50% of VOCs from cleaning solution for both heatset and non-heatset equipment remains in the rags or wipes and emitted at the point of cleaning, if the vapor pressure is less than 10 mmHg or less at 20 °C.
  • Document the offsite reuse, recycling, and disposal of VOC-containing materials, including actions and quantities, to credit the VOCs not emitted at your location.