Normal batteries are filthy. I'd really encourage everyone to stop using them. You can get good, rechargeable lithium polymer batteries here:
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10 bucks for the 350mAH battery, 10 bucks for the charger... that's two Duracells at Walgreen. They bigger ones haven't been in stock for a long time.
Beyond the environmental impact of the batteries, they require me to split my jack order, reducing the bulk discount. And I have to buy clips. And I have to buy holders (because I don't want the battery flopping around). But that's just my end, and the cost per pedal really isn't very high.
I've been doing a bit of research for a cost-effective way to make rechargeable pedals that could easily be retrofitted into existing pedals. So far, no luck, but I'm still looking. I'd imagine you could just reverse-engineer the charger on the site I linked above and use those batteries.
Getting more into the environmental stuff, the finishing process on these pedals is 100% solid (no VOCs) other than the glue used on the labels (I'm looking for a new one-- this will do for now).
I tried to find recycled aluminum enclosures. pedalenclosures.com has some really nice ones, but I can't deal with the sloped face for this design. I'm hoping Hammond is a fairly responsible company. The ones I'm using say "Made in EU" on them. I'd assume the environmental laws are much stricter there than even the US, and especially China where most enclosures come from (made by New Sensor/EHX). If I find reasonably priced recycled hammond clones, I'll try them out.
After some research on solder, the most environmentally friendly is a lead free Tin/Copper alloy, according an EPA report. I'm using Tin/Copper/Silver, which is apparently the worst because of how filthy silver mining is. I didn't know that at the time I bought it, but I have it now. It's a bit better, as solder, than the standard Tin/Copper. If the silver is recycled, the environmental impact is much less significant. I'll likely switch over once I run out-- I don't think the differences will really matter in a stomp box.
The gnomes are total hippies. They get into this stuff. I just wish I could keep them from hittin' the bong at work.