Zero Waste Logo The Zero Wate Network the University of Texas at Arlington Center for Environmental Excellence Environmental Training Institute Logo  

Join Us on:

Social Network Nav Bar

Lean and P2 Workshops

Nov, 14-16, 2017,

Dec. 5-7, 2017




Environmental Management Systems Workshops

Lake Charles
Sep. 26-29, 2017

Dec. 12-15, 2017



Case Study Database

           Add Story    |    Search Case Studies    |   


Kaspar Wire Works, Inc

Year Submitted: 2011

Process: Wastewater Treatment

Industry: Metal Finishing

Wastes Reduced: Sludge

Location: Shiner TX

No. of employees: 300

Contact: Douglas Herber

Phone: 361-594-3327


Kaspar Wire Works, located in Shiner, Texas, is the largest manufacturer of newspaper vending machines in the world. As part of our desire to prevent pollution and to reduce environmental costs, we decided in 1998 to look at how to improve the wastewater treatment system. The results of our efforts reduced our wastewater treatment costs by 94% and sludge generation by 40%.

P2 Application:

We realized a lot of money was spent on wastewater treatment chemicals and sludge disposal. After extensive research, an electrocoagulation (EC) system was purchased and redesigned to meet stringent discharge limits on metals such as chromium, copper and nickel. The EC converts hexavalent chrome to trivalent. As a result, we no longer need sodium metabisulfite for chrome reduction, thus eliminating the use of the chemical. We also significantly reduced calcium chloride, sodium hydroxide, and sulfuric acid. The EC system prevented the presence of hundreds of thousands of pounds of soluble sodium salts being discharged to the city.

Details of Reductions

  • 18,000.0 - lbs of   Sodium Metabisulfite
  • 80,000.0 - lbs of   Calcium Chloride
  • 90,000.0 - lbs of   Sodium Hydroxide
  • 50,000.0 - lbs of   Sulfuric Acid
  • Wastewater Sludge
    Comments: 40% reduction

Additional Information :

The EC system removes more metals and oil and grease than the previous wastewater treatment system and at a reduced cost. The sludge generated from the EC system was reduced by 40% and it is now being sent off-site for recycling. Initially the EC system did not work as expected. The system was redesigned and improved. As a result, several patents were obtained and a spin-off company called Kaselco was formed to market and sell the new technology. The EC system performance was evaluated and verified by an independent third-party as part of the U. S. Environmental Protection Agency's Environmental Technology Program. Kaspar serves as a good example of how a company can receive multiple benefits by reducing their environmental impacts and create additional business opportunities for their efforts.

Source: TCEQ

SHEP Shield
Health and

ERP Shield

ESP Shield

EMP Shield

Attend a workshop and
earn credits toward a
Professional Certification



The Zero Waste Network is one of eight Pollution Prevention Resource Exchange P2RxCenters , serving as a national network of regional information centers: NEWMOA (Northeast), WRRC (Southeast), GLRPPR (Great Lakes), ZeroWasteNet (Southwest), P2RIC (Plains), Peaks to Prairies (Mountain), WSPPN (Pacific Southwest), PPRC (Northwest). We are a proud member of the National Pollution Prevention Roundtable.

National P2 Roundtable Logo