1. 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

2. 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

3. 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?

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

5. Materials: a global concern
RECP Clubs: resource materials
What ?
July 2015
Materials: a global concern
Continued rise in global materials consumption
80% increase between
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

6. 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

7. 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

8. ... 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!!

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

10. 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

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

12. 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

13. Why ?
Business Examples
National examples

14. 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

15. 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?

16. 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?

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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.

25. 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

26. 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

27. 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.

28. 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

29. 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

30. 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

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

32. 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 ?

33. 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