1. Cleaner Production

3. HOW LONG DOES IT TAKE TO DECOMPOSE ?
Eye opener…..
Do you Know..
HOW LONG DOES IT TAKE TO DECOMPOSE ? 
Just think of the list below before you throw something on to the soil.              Paper Towel weeks   Banana Peel weeks      Paper Bag - 1 month        Newspaper months          Apple Core - 2 months        Cardboard - 2 months          Cotton Glove - 3 months       Orange peels - 6 months       Plywood years           

4. Wool Sock years          Milk Cartons - 5 years        Cigarette Butts years          Leather shoes years        Tinned Steel Can - 50 years          Foamed Plastic Cups - 50 years        Rubber-Boot Sole years          Plastic containers years        Aluminum Can years          Plastic Bottles years        Disposable Diapers years          Monofilament Fishing Line years   Plastic Bags years          Glass million years    

5. What is the Problem?
“The major cause of the continued deterioration of the global environment is the unsustainable patterns of consumption and production, particularly in industrialized countries, which is a matter of grave concern, aggravating poverty and imbalances.”
Agenda 21 (Chap. 4.3), Earth Summit, Rio 1992

6. What is the Magnitude?
“It is simply impossible for the world as a whole to sustain a Western level of consumption for all. In fact, if 7 billion people were to consume as much energy and resources as they do in the West today we will need more than one planet to satisfy all our needs.”
Gro Harlem Brundtland, 1994

7. Sustainable Development: a long-term issue
If we go on with current production and consumption patterns,
Two planets are needed by 2050
1900
2002
2050
2100

8. What can we do?? Traditional Sri Lankan Approach Steam & Water leakage
A traditional DC mill at Wennapuwa

9. Cleaner Production Content
Driving forces for implementing CP.
What is CP?
CP Benefits.
Steps of CP Audit & implementation.
Examples of CP applications.

10. Driving forces for implementing CP
Customers
Standards
Cost reduction
Laws and
regulations
Employees
Envt. organizations
Increased efficiency
Financial sector
Environmental quality

11. What is CP? Definition
Cleaner Production is the continuous application of an integrated preventive environmental strategy to processes, products, and services to increase overall efficiency, and reduce risks to humans and the environment. Cleaner Production can be applied to the processes used in any industry, to products themselves and to various services provided in society.

12. What is CP?
CP refers to a mentality of how goods and services are produced with the minimum environmental impact under present technological and economic limits.
Cleaner Production is a 'win-win' strategy. It protects the environment, the consumer and the worker while improving industrial efficiency, profitability, and competitiveness.

13. What is CP?
The key difference between pollution control and Cleaner Production is one of timing. Pollution control is an after-the-event, 'react and treat' approach. Cleaner Production is a forward-looking, 'anticipate and prevent' philosophy.

14. CP at a glance! Before After
High consumption of raw materials and resources, generating much waste
After
Use only necessary raw materials and other inputs, apply strategic process changes, reduce waste while increasing productivity

15. Environmental Management Hierarchy
Minimizing waste
Before
After
Re-use (in the process)/
Recycling
Pollution Prevention
or CP
Treatment and
disposal

16. Benefits of CP Reducing cost of production.
Reducing environmental impacts at source.
Reduce waste treatment cost.
Improved product/service quality.
Optimal consumption of raw materials and Improved production efficiency.
Higher profits.

17. Promoting health and safety. Reducing the load of public inspection.
cont. CP Benefits
Enhancing good relations among workers and between industries and the local community.
Promoting health and safety.
Reducing the load of public inspection.
Creating business advantages.
Better image of your business.

18. CP philosophy Stop waste Prepare inventory of sources
Where is waste generated?
2. Reasons why waste is generated
Why waste is generated?
4. Select most suitable suggestions & implement
Stop waste
3. What are the solutions- Propose
How to stop waste generation?

19. Steps of CP implementation
Interest in CP
1. Planning and setting up a CP Team
6. Implement and sustain
2. CP Audit
5. Asses Technical & Economic feasibility
3. Data analysis
4. Develop & Select CP
options

20. Proven Economic and Environmental benefits from CP on Wastewater Mgt.
A leading food company, located in Kandy, the company does a profitable business.
However, it was facing grave wastewater treatment and disposal problem.
The out-put quality of wastewater did not meet the environmental regulations. The company was very keen to reduce their overall production costs & build the image by reducing wastage of water and treating wastewater.

21. This saving is more than enough to treat remaining wastewater.
Cont…
A CP assessment was carried out in the plant in order to identify the wastewater streams. The audit team studied wasteful outflows.
Many opportunities for implementing CP options were recommended immediately.
The company is in the process of minimizing their water use from 125 m3/day to less than 25 m3/day. This will save 80% of their water bill.
This saving is more than enough to treat remaining wastewater.

22. Cont…
A profit making food and beverage company in the Kelani River basin has a proper water treatment plant. Quality of treated water is up to the standards. They were keen on CP!!
After doing CP, they are planning to reduce water and energy consumption by at least 15%.
A coconut based product factory, generating 15m3 of wastewater a day is facing a huge problem of waste water. They are very keen on environmental conservation in their business.
A CP option was proposed to convert 5 m3 of wastewater into a value added product. An additional income of Rs. 300, could be generated per day.

23. OGM Rice flour Mill at Mawanella –Investigation
According to the baseline data Rs (0.07 Kwh) value of electricity and Rs (0.260 Kg) value of coconut shell is needed for producing 1 kg of roasted rice flour.
The annual wastage of rice flour is kg with the value of Rs
The highest wasting steps were manual roasting (30%) and
shifting or grading (27%).
Average annual coconut shell wastage is about 2460 kg equivalent to Rs
The calculated annual electricity wastage was Kwh, equivalent to Rs

24. Myths About CP Good only for large companies
Requires huge amount of money
Requires modern technology
Requires qualified professionals
Automation is a must
One time activity
Limited potential

25. Fear of being seen as fool
CP Mental Blocks
Fear of being seen as fool
Fear of disturbing tradition
Fear of being alone
Fear of being criticized
Fear of being misused
Fear of resistance to change
Fear of making mistakes
Fear of being a guinea pig

26. Thank you For Your Interest in Saving The Earth
CP FIRST
TREATMENT SECOND
Thank you For Your Interest in Saving The Earth
MINIMUM WASTE
MAXIMUM
PROFIT

27. 1. Planning and setting up a CP Team
Objectives
To establish a policy to be used as a guideline for implementation
To have a CP team working as a core group

28. A good CP policy Is approved by the top management of the factory.
Stresses waste reduction at source.
Has definite target for waste reduction per production unit.
Has a timeframe.
Is related to legal regulations.

29. Examples of good CP policies
Our factory is aiming to reduce water consumption down to 2L per 1L of Processed milk at the end of 2015 .
Our factory aims to reduce milk waste in yogurt production by 50% at the end of year 2015.

30. Responsibilities of the CP team
Gather data from various sources, construct production flowchart and decide scope of unit operations
Prepare mass balance of production processes and unit operations of interest
Collect additional data required for a mass balance
Present CP options
Study feasibility of various options
Set up steps for implementing selected options
Assess and monitor

31. Members of a CP team CP team manager Factory Manager
CP team members 1. Production Head
2. Utility Head
3. Purchasing Head
4. Accounting Head
5. Pollution Prevention Officer
(Team Head)
6. Other interested employees

32. Qualifications of a CP team member
Responsible
A good team player
Observant
Eager to learn
creative
Respects opinions of other people
Working for the common cause
High academic Qualification
Extensive work experience

33. 2. CP Audit
Comprises:
Pre-assessment
Detailed audit

34. Pre-assessment Objectives
To construct production flowchart and gather basic information
To set the scope of unit operations within the production process
Survey and look for areas of loss, both quantitative (how much?) and qualitative (what are the characteristics? )
To set more appropriate CP targets

35. Sample of a production flowchart
Raw milk
Cleaning water/
acid/alkaline
Lost milk/
Effluent from
cleaning
Raw milk
reception
Pasteurization
Milk left in pipes/
Effluent from
cleaning
Cleaning water,
acid/alkaline
Filling
Lost milk/
Film/defective
carton
Film/carton
Cold room
Spoilt milk
Ready to drink milk

36. Detailed audits Objectives
To prepare mass balance and/or energy balance for each unit operation
Collect data necessary for proposing CP options

37. How to prepare a mass balance
Total input = total output
Decide the scope of unit operations
Study inputs entering unit operations
Are there chemical reactions in the unit operations?
Study output from unit operations
Is recycling practiced?

38. Sample of input-output of a unit operation
Raw materials
Air emission
Catalyst
Unit
operation
Water/air
Products
Energy
By-products
(includes waste to be recycled/recovered)
Re-use
Effluent
Waste/chemicals to be disposed of
Recycling in other processes
Excess materials
Source: Audit and Reduction Manual for Industrial Emission and Wastes, UNIDO

39. Possible areas for waste reduction
Types and characteristics of raw materials
Raw material reception; quality and amount check
Use and storage of raw materials
Transportation of raw materials and products (in solid, liquid and gas forms) in the production process
Control of production processes
Use of water in cleaning and cooling
Product storage

40. 3. Data analysis and feasibility study
Objectives
To propose CP options
To find CP options suitable for the factory (both technically and economically)

41. CP options can be found from:
Machine operators.
Comments from other factory employees.
CP team.
Case studies from similar industries.
Case studies adapted from other industries.
Experts.
Suppliers of raw materials and equipment.
Clients/markets.

42. Few examples for different CP options for saving water
When cleaning factory floors, sweep off dirt and scraps before hosing down with water.
Check for leaks in various connections, e.g., pipes for raw, soft and cold water, and repair immediately if leaks are found.
Plan production process so that minimal washing is required.

43. Feasibility study Technical Economic Is it scientifically feasible?
Is there available technology?
Are there available implementers?
Economic
Is investment required?
How much is the expected savings?
What is the payback period?

44. Environmental impact and safety
Is inefficient consumption of raw materials and energy reduced?
Is amount of waste incurring treatment costs reduced?
Is amount of waste discharged to the environment reduced?
Is working condition improved?
Are accidents and illnesses reduced?

45. 4. Setting procedure and implementation
Objectives
To have steps in implementing selected CP options
To proceed within a timeframe

46. Sample of CP implementation procedure

47. 5. Assessment
Objective
To summarize results and start new options or re-start the cycle

48. Sample of progress monitoring

49. Types of CP options Adjustment of operations and management
Reuse and internal recycling
External recycling
Partial adjustment
Total change
New product improvement
Product chain system improvement

50. More examples for different CP options for saving water
Ensure that float valves are properly functioning.
Where possible, use high-pressure nozzle on water hoses.
Avoid cleaning by overflow system; counter-flow system is preferable.
Check quality of water used and use appropriate type of water.
Consider returning condensate.
Water used to cool machines should be reused.
Install water meters at key points so that loss and production efficiency will be known.