RECP Clubs: resource materials July 2015 Better Business – Cleaner Environment – Green Economy Resource Efficient and Cleaner Production (RECP) for Small and Medium Businesses Developed by the United Nations Industrial Development Organization under the Regional RECP Demonstration Programme for Eastern Partnership Countries, with funding support from European Union under EaP GREEN Initiative July 2015 EaP GREEN RECP Demonstration Component

RECP Clubs: resource materials Today’s Workshop July 2015 Assess progress on self assessment for Water Efficiency Why? Environmental burden and costs of water use and waste water generation What? Diagnosis of the use of water and effluent generation Next Step Priority RECP options to reduce water use and waste water generation Proceed to Materials and Waste” Overview What are implications of inefficient use of materials Why to manage efficiently materials and waste How to avoid, reduce and recycle waste Discussion and assignment EaP GREEN RECP Demonstration Component

Water Efficiency Report back from self assessment Baseline situation Understanding water use and effluent generation Major water users and waste water sources Water diagnosis What are the main causes for high water consumption and waste water generation? Where is water lost? What are the costs of water losses and effluents? RECP Options to increase water efficiency and minimize effluents Immediate and other options Data gaps and support needs?

Module 4 – Materials and Waste RECP Training National Experts October 2014 Module 4 – Materials and Waste What? Why? How? EaP GREEN RECP Demonstration Component

Materials: a global concern RECP Clubs: resource materials What ? July 2015 Materials: a global concern Continued rise in global materials consumption 80% increase between 1990-2008 Business as usual not an option for future Tripling of global material consumption by 2050 assuming that all countries catch up to OECD levels from 2030 onward All stages of material use cause environmental impacts Energy use Land use and depletion of natural resources Air and water emissions and waste generation Political factors Balance of trade Critical minerals Green economies around the world?, UNIDO, 2010 EaP GREEN RECP Demonstration Component

Materials (ultimately) become Waste What ? Materials (ultimately) become Waste Municipal Solid Waste 2002: 2.9 billion city dwellers generated 0.68 billion ton waste (0.64 kg pppd) 2012: 3 billion city dwellers generated 1.3 billion ton waste (1.2 kg pppd) 2025: 4.3 billion city dwellers are expected to generate 2.2 billion ton waste (1.42 kg pppd) Total waste generation to triple by 2100 to 12 million tonnes/day Nature, 502, 615–617, (31 October 2013) What a waste: a global review of waste management, World Bank 2012

Municipal solid waste - garbage of gold? What ? Municipal solid waste - garbage of gold? In developing countries most of waste is disposed in open dumps The world market for municipal waste, from collection to recycling is estimated at 4 billions tonnes /year Only a quarter from 4 billion tonnes/year is recycled and recovered World bank, 2012 European countries are making progress on waste recycling Recycling industries had a turnover of 32 billion Euro in 2004 and increased to 60 billion Euro in 2010 Employment in the recycling industry increased by 45% between 2000 and 2008 Highest recycling rates in Austria and Germany EPA, 2012

... An extended view waste = non product output What ? ... An extended view waste = non product output Different sources non-conforming products non-conforming material process loss second quality contaminated solids scrap material packaging rework stock loss washings expired materials un-necessary supply dust Ultimately, you can only trash what you bought in the first place!!

Waste hierarchy What ? Most favorable approach I. Avoid II. Reduce III. Recycle IV. Dispose Least favorable approach

Business concerns Cost to business Risk to business What ? Business concerns Cost to business Prices of raw and processed materials Cost of wasted materials, waste disposal and treatment Environmental taxes (packaging, toxic materials) Risk to business Lost productivity due to interrupted supply of materials or lacking access to waste management Volatility of materials and waste prices, due to market and political factors Suspension of operating licenses due to illegal waste disposal Impact on environment Resource scarcity, land use and energy requirements Waste burden, air pollution, water and soil

Materials and waste : national concerns What ? Materials and waste : national concerns Sum up national concerns in regard to materials use and waste

Efficient materials use and waste minimization benefits Why ? Efficient materials use and waste minimization benefits Direct and indirect savings material and waste cost Reduce direct Indirect savings: Reduce handling cost Reduce regulatory costs Business security Compliance with regulation Reduce dependence on volatile material prices Reduce long term liabilities for waste Social responsibility Employees motivation Reduce, Recycle & Reuse culture Improved relations with community

Why ? Business Examples National examples

Challenges to Material Efficiency & Waste Minimization RECP Clubs: resource materials Why ? July 2015 Challenges to Material Efficiency & Waste Minimization Limited awareness Actual material use and waste generation and their associated costs Impacts of behaviour and process conditions on materials use and waste generation Lack of knowledge Specific knowledge on materials and waste Reliable benchmarking data Material saving and waste minimization techniques and practices Lack of infrastructure Waste disposal and treatment facilities Recycling solutions for different types of waste Poor waste management practices Waste logistics including waste segregation Knowledge of waste obligations EaP GREEN RECP Demonstration Component

RECP for Materials Efficiency & Waste Minimization How? RECP for Materials Efficiency & Waste Minimization Source: Where is material used for what purpose and with what material losses? Cause: What factors influence material use and losses? Option: How to minimize the causes of material use and losses?

Understanding material use and waste generation How? Understanding material use and waste generation Source Main questions: Where is material used and for what purpose? What types of waste are generated and where? How is waste managed? Which waste legislation applies to different types of generated waste?

Data collection Overview of input materials Overview of waste output How? Data collection Source Overview of input materials Types of materials Monthly and annual consumption Overview of waste output Types of waste flows Monthly and annual waste quantities Materials cost data Cost of input materials Cost of processing Waste cost data Cost of waste disposal monthly/yearly Income from recycling Waste containers cost /rental Handling cost (employee time used to collect and handle waste) Waste storage cost

Source of data Input materials data Waste output data How ? Source of data Source Input materials data Accounting documents Documents from suppliers Internal records and software Waste output data Waste transfer notes Waste disposal /recycling weighting notes Internal records Calculations

If wastes are mixed up …sort them to understand the waste challenges! How ? Waste sort Source If wastes are mixed up …sort them to understand the waste challenges! Conduct a waste sort for an illustrative period or activity to: identity the waste types estimate waste quantities on basis of fractions in the sorted waste batch Provides a detailed profile of types and amounts of waste Make sense when waste is not sufficiently segregated

Root causes How? Cause LOW material efficiency & HIGH waste generation PLANT PEOPLE PROCESS INPUTS Process Control Equipment Design Technology Choice LOW material efficiency & HIGH waste generation Internal Value External Value WASTE PRODUCT

RECP Training National Experts How? October 2014 Root Causes Cause Root Cause Category Some examples (product breakage in ceramics production) Process Inputs Quality of incoming clay People Inappropriate handling of molded clay Adherence to recipes for clay preparation Plant Process Control Operating temperature control for clay firing Equipment Wear of conveyors on molded and fired product Technology Type of burners in kiln Product Inherent physical strength of product designs Waste Internal Value Unfired clay – can replace virgin clay External Value Fired ceramics – can have value as fill material EaP GREEN RECP Demonstration Component

RECP Training National Experts How ? October 2014 Typical causes Cause Plant Inefficient technology Inadequate automation and process control Poor production planning (frequent change-overs, cleaning, start up and shut down) Poor maintenance Malfunctions Leakages Process Inputs Poor quality of raw and auxiliary materials Excess packaging Inefficient purchasing Poor handling and transport of goods Inadequate purchasing and warehouse management People Lack of awareness and motivation Lack of job instruction Improper behavior No control of cleaning company personnel Waste No waste segregation Poor waste logistics No internal / external recycling solutions No waste procedures in place Product Product design Low product quality Improper product dispatch Excessive packaging EaP GREEN RECP Demonstration Component

Better Process Control How? Option Generation Option PLANT MODIFICATION HOUSEKEEPING INPUT CHANGE Better Process Control Equipment Modification HIGH material efficiency & LOW waste generation Technology Change On Site Reuse Useful Byproduct UTILIZATION PRODUCT MODIFICATION

Option Generation How? RECP Practices Input Change Good Housekeeping Some examples (product breakage in ceramics production) Input Change Better selection of clay, with less impurities Good Housekeeping Standard operating procedures, appropriate implements to handle fragile items Plant Modifi-cation Process Control Improved control of firing temperature in the kiln Equipment Modification Modify conveyers and handling system to reduce wear on products Technology Change Energy efficient burners Product Modification Review/modify product forms to eliminate weak points Dematerialize product - thinner Reuse On Site Reuse Recover un-fired clay for internal reuse Useful By Product Offer ceramic waste as fill material – concrete, road etc.

RECP Training National Experts How ? October 2014 Typical options Option Plant modification Efficient technology /equipment Improve planning and controlling Improve automation and process control Preventive maintenance Input change Better selection of input materials Better quality of input materials Avoidance of toxic materials Efficient purchasing Good housekeeping Waste segregation procedures Systematic education Efficient waste logistics Control of cleaning personnel Stock management Waste monitoring Waste utilization Waste segregation Internal / external reuse and recycling solutions Product modification Improved product design Better quality of product Optimized distribution and packaging (lightweight, squeeze, recycled, recyclable) EaP GREEN RECP Demonstration Component

Materials Efficiency & Waste Minimization Incoming Goods Improved inspection and strict acceptance criteria Minimization of inventory (Just in Time), including its diversity First In First Out warehouse management Adequate storage conditions with controlled access Purchase in appropriate quantity and with minimum packaging Product Dispatch First In First Out warehouse management Adequate storage conditions with controlled access Production planning to follow sales/order

Materials Efficiency & Waste Minimization Production Waste Extend product runs to minimize waste from start up and shut down Schedule product runs to minimize cleaning Recover cleared out product for reuse in next batch Reduce stress from equipment on products Maintain even process conditions (better mixing, heating, cooling) Use of Auxiliaries Fit for Purpose to extend use and minimize consumption and waste Minimize diversity, where possible Use dosing systems, where appropriate Coolants, lubricants, cleaning agents, etc.

Materials Efficiency & Waste Minimization Office Waste Go paperless Select reusable/refillable products Use recycled paper and office products Waste segregation Staff motivation Canteen Waste Reusable cups & cutlery Buy local Avoid single dose packing Use recycled paper

Taking our pulse.. Materials Use and Waste Generation In your opinion Comments/Suggestions (when last checked?) Is your company aware of present situation? Is your company aware of alternatives (techniques, sources, etc.)? Materials supply Product ingredients/inputs   Production auxiliaries Packaging materials Cost of materials supply Material uses Production processes Supportive activities Packaging Material losses Areas where materials are lost Costs of material losses Waste Streams Sources of waste Composition of different waste streams (Actual) cost of waste

Material use 2. Direct Material Use 2 A: Materials used in product   2 A: Materials used in product Please list all products enclosing the specified type of material ID Material description Place of use (which process step?) Purpose of material in the product Physical units of production (ton, pieces/yr) Designed material requirement per unit of production (ton, piece/unit of product) Annual Physical Output (nr of products) Theoretical annual material requirement (kg,ton, piece/yr) Actual annual material consumption (kg,ton, piece/yr) Material loss (% of theoretical material requirement) What factors influence the material consumption for this application? 1 #DIV/0! 2 3 4 5 6 7 8 9 10 Total accounted material use in product % of total material consumption

Next step Introduction of self assessment on water and waste water Identification of possible bottlenecks

Wrap Up – Take Aways The companies are dependent on raw materials in order to produce their goods. The rates of extraction lead to depletion of natural resource stocks and scarcity of indispensable materials Waste is the material paid once by the business Material efficiency and waste minimization contributes to cost reduction, business security and reduction of environmental pollution What ? Why ?

Wrap-up – Take aways How ? Improving material efficiency and minimizing waste requires: To understand: Material use, consumption and cost Types of waste, volumes and sources To identify: Factors influencing material use, inefficiency and losses Factors influencing waste generation Causes for inefficiency, material loss and waste generation To generate and implement RECP options to increase material efficiency and minimize waste Source Cause Option