The European Regional Development Fund (ERDF) Resource Efficiency Training Add venue Name of...

The European Regional Development Fund (ERDF)

Resource Efficiency Training

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ENWORKS Resource Efficiency Programme

Introductions

• Name & Job / Role

• Company name & brief description of operations

• What is your company’s major waste?

• What do you hope to get out of today?


Module 1 - Energy


Learning objectives

• To gain a basic understanding of:• energy consumption• monitoring• control

• Identify potential savings & share best practice


Why focus on energy?

• All companies use some form of energy – gas, electricity & fuel

• Because most companies can reduce their energy bills by 20%

• Because legislation and other Government initiatives are forcing us

• Often a company’s major environmental impact

• Because £12 billion of energy is wasted in the UK every year (Action Energy)


Impact of electricity

• Company paying £5,000/year• Equivalent to:• 100,000 kW consumption (5p per kW)• 44 tonnes of carbon dioxide (or 12 solid

tonnes of carbon)• Volume of 250 double-decker buses (CO2)• Weight of 8.1 elephants (or 587 men)• 73,997 miles in a car using petrol at 30mpg• Running Titanic for 2.6 hours on full steam


What are the benefits of reducing consumption?


Example of savings potential

• Turnover £1 million• Profit (10%) £100,000

• Energy Cost (4%) £40,000• Savings potential (20%) £8,000

• Equivalent to 8% rise in profits• Turnover increase of £80,000


Other benefits

• Improved reliability – plant/service

• Better working environment

• Increased output

• Competitive advantage


Energy management

1. Make someone responsible

2. Establish the facts

3. Compare your performance

4. Plan & Organise

5. Pay less for your energy

6. Use less energy

7. Control & Monitor


Or

• Consider:• Management• Monitoring• Actions• People


Management - Buy it cheaper

• Energy contract negotiation

• Simple tendering process

• Make sure you are familiar with components of energy bills• beware of estimates • electricity maximum demand

• Checking the small print (e.g. notice required)


Monitoring - Where is it being used?

• 3 main areas:• Process – machines, tools, process

heating, furnaces• Services – compressed air, steam,

hot/cold water• Building Services – space heating,

ventilation, lighting


Monitoring - Where is it being used?

• Produce an energy map

• Identify the five biggest energy consumers in your company

• Use pareto rule

80% of energy used by 20% of process


What to monitor?

• Electricity• Day Units• Night Units• Availability & Maximum Demand• Power factor

• Gas• Units• Degree Days


Monitoring - Day and night units

0

10,000

20,000

30,000

40,000

Day Units (kWh) Night Units (kWh) Total Units (kWh)


Maximum Demand

• The peak instantaneous demand during a specific period (kW or kVA)

020

40

60

80

100

120140

7 9 11 13 15 17 19 21 23 1 3 5 Hours

kVA

Monitoring


Availability

• The reservation of an agreed capacity with your supply company (kVA)

• Should be set at approximately 10% above maximum demand

0

20

40

60

80

100

120

140

7 10 13 16 19 22 1 4 hours

kVA

Monitoring


Availability and maximum demand

0

100

200

300

400

Availability (kVA) Maximum Demand (kVA)

Cause of problem:Equipment failure

Additional cost due to equipment failure


(kVA)(kWh)

(kVArh)

BeerReal Beer

Froth

Power Factor & Reactive Power Charge

Monitoring


Power factor

0.5

0.6

0.7

0.8

0.9

1.0

Equipment Failure


Monitoring - Half-hourly Metering

• Available to above 100 kW Maximum Demand market • Approximately £1,000 per month

• Metering company take a reading every ½ hour

• Smaller consumers can hire portable metering equipment


0:30 1:00 1:30 2:00 2:30 3:00 3:30 4:00 4:30 5:00 5:3001/10/1999 1 1 1 1 1 1 1 1 1 1 102/10/1999 1 1 1 1 1 1 1 1 1 1 103/10/1999 1 1 1 1 1 1 1 1 1 1 104/10/1999 1 1 1 1 1 1 1 1 1 1 105/10/1999 2 2 2 2 2 2 2 2 2 2 206/10/1999 2 2 2 2 2 2 2 2 2 2 207/10/1999 2 2 1 2 1 2 2 2 2 1 208/10/1999 2 2 2 2 2 2 2 2 2 2 209/10/1999 1 1 1 1 1 1 1 1 1 1 110/10/1999 1 1 1 1 1 1 1 1 1 1 111/10/1999 1 1 1 1 1 1 1 1 1 1 112/10/1999 1 1 1 1 1 1 1 1 1 1 113/10/1999 2 2 2 2 2 2 2 2 2 2 214/10/1999 2 2 2 2 2 2 2 2 2 2 215/10/1999 1 2 1 2 2 1 2 1 1 1 116/10/1999 0 1 0 1 1 0 1 0 1 1 017/10/1999 1 1 0 1 0 1 1 1 1 1 018/10/1999 0 1 0 1 1 0 1 0 1 1 019/10/1999 2 2 2 2 2 2 2 2 2 2 220/10/1999 2 2 2 2 2 2 2 2 2 2 221/10/1999 2 2 2 2 2 2 2 2 2 2 222/10/1999 1 2 1 1 1 2 1 2 1 2 223/10/1999 0 0 0 0 0 0 0 0 0 0 024/10/1999 0 0 0 0 0 0 0 0 0 0 025/10/1999 0 0 0 0 0 0 0 0 0 0 026/10/1999 1 2 1 1 2 1 1 2 1 1 127/10/1999 2 2 2 2 2 2 2 2 2 2 2

Data received in spreadsheet form


1/2 hourly readings for 6 Months

0

50

100

150

200

250

DATE

KW

h


1/2 hourly consumption profile - monthly

0

50

100

150

200

250

September

KW

h


1/2 hourly electrical consumption profile - weekly

0

50

100

150

200

250

04/09/2000Monday

05/09/2000Tuesday

06/09/2000Wednesday

07/09/2000Thursday

08/09/2000Friday

09/09/2000Saturday

10/09/2000Sunday

DAY

KW

h


1/2 hourly consumption profile - daily

0

50

100

150

200

250

KW

h


How does consumption vary against production?

• Monitoring against time valuable• However, peaks and troughs can be

misleading

Weeks

KW

h e

lect

rici

ty t

o o

ven A

B


How does consumption vary against production?

Production figures

KW

h t

o O

ven

(B)

(C)

(A)


Energy Consumption -v's- Production

0

500

1000

1500

2000

2500

0 20 40 60 80

Production (tonnes)

Elec

trici

ty U

se k

Wh

Y = 22x + 789

C

m1

m2


Base load - Fixed costs

• C on the graph

• Start-up losses

• Operating losses such as compressed air leaks

• Equipment running despite absence of any load

• The use of any equipment that doesn’t add value to the product - ancillary equipment


Unit costs - Variable costs

• M on the graph

• Process Yield

• Off-spec, scrap or non-saleable product

• Product re-working

• Product finishing


Monitoring - Sub-metering

• Separate specific areas• Office• Production area

• Data loggers• Specific pieces of plant, machinery


MonitoringCompare performance - BenchmarkingBuilding Type Good Poor

Offices

Cellular

Open plan

Air-conditioned

(£/m2)

3.74

4.70

8.40

(£/m2)

6.47

7.79

14.92

Factories

General

Light

warehouse

(£/m2)

7.80

5.50

4.00

(£/m2)

10.60

9.20

5.60


Actions No & low cost solutions

• Energy walk-round• Procedures ignored?• Repairs or maintenance needed• Overheating• Lighting• Draughts• Regular maintenance/servicing


No & low cost solutionsElectric motors

• Often account for 60% of electricity costs

• Common problems• Oversized motors• Poor power factor/performance

• Common solutions• Motor audit – numbers, size• Maintenance• Buy high-efficiency


No & low cost solutions Compressed air

• 10 times more expensive than electricity • hole the size of pinprick in an air line can =£120

per year

• 30-40% compressed air leakage rate is common - 10-15% should be the target• Good housekeeping• Turn off when not needed• Leakage detection• Minimise

• Audit – see manual


No & low cost solutions Fuel use

• Regular servicing

• Monitor MPG / driver performance

• Route planning• software

• Conversion to cleaner fuels • Powershift


Actions - Equipment investment

• High efficiency motors• Variable speed drives• Energy efficient lighting• Building insulation• Financial assistance• Enhanced capital allowances• Loans• Capital grants


People - Myths and legends

• “Leaving the lights on is more economical than switching them off” • “Leaving equipment such as compressors,

machine tools and other motors on is more economical than switching them on and off all the time” • “Office equipment such as computers use

hardly any electricity”


People - Get them involved

• Measuring

• Monitoring

• Awareness raising

• Maintenance

• Planning


Case Study - Wild Manufacturing

• Presswork company – 180 employees• EMS driven – energy was key

cost/environmental impact• Formed committee• Measured• Set targets

• 10% utilities reduction in first year• Awareness raising campaigns

• “switch off, turn off, save it”



• What they did• Focused on ‘common sense’

housekeeping issues• Check & repair procedures for

compressors• Fitted light sensors• Sealed gaps around windows & doors• Kept traffic doors shut as much as possible• Publicised consumption data to staff



• What they achieved (first year)• Reduced electricity costs by 13%• Reduced gas costs by 7%• Vastly improved staff awareness

• SAVINGS IN £££££££


Energy support

• Action Energy• Helpline – 0800 58 57 94• Publications• Interest Free Loans• On-site surveys

• Must have consumption £50,000+• www.actionenergy.org.uk


Workshop 1

Energy Auditing


Workshop 2

Understanding Your Energy Bills


Workshop 3

Energy Efficiency Action Plan


Module 2 - Packaging


Why focus on packaging?

• Legislation

• It is expensive• As a raw material• To dispose of

• Offers a lot of opportunity


Learning objectives

• To help you save money by optimising packaging

• To understand the legal obligations for packaging use and waste

• To provide ideas to reduce, re-use and recycle packaging materials


What is packaging?

• “All products made of any materials of any nature to be used for the containment, protection, handling, delivery and presentation of any goods” The Producer Responsibility Obligations (Packaging Waste) Regulations, 1997


What is packaging?

Packaging Material

Stretch Wrap Pins Shrink Wrap Cards

Sacks Air bags Bottles Pallets Banding

Slip sheets Edge protectors Bubble Wrap Dividers Cores Padding Drums Bedding Trays

Cartons Crates Crumpled paper Containers

Polystyrene chips Adhesive tape Strapping


Why do we use packaging?

5 major reasons

• To protect the product• To prevent contents escaping• To be compatible with

storage/handling systems• To identify products• To market


Packaging management

• Packaging Management can be defined as:

“ a systematic approach that allows the most efficient use of packaging and packaging materials in order to reduce costs and material wastage without compromising product protection, handling and storage”


Why manage? - Legislation

• 2 Specific Regulations in UK:• Producer Responsibility Obligations

(Packaging Waste) Regulations• Packaging Essential Requirements

• Landfill Tax

• Duty of Care


Why manage? - Other benefits

• Supply-chain pressures• good communication

• Improved company image

• Improved environmental performance

• Can demonstrate good environmental management system


TRUE COST OF

PACKAGING

Packaging materials loss

Treatment and disposal

Storage

Transport Materials handling

Monitoring and analysis

Why manage?

Compliance

Purchase of packaging


Minimise your packaging

• Eliminate – prevention rather than cure

• Reduce

• Re-use

• Recycle

• Disposal as last resort

• ALWAYS CONSIDERING ‘FIT FOR PURPOSE’


Eliminate

• Is it really needed?

• Reduces all costs

• Any company examples?


Reduce at sourcePackaging design & optimisation

• Match the level of packaging to the level of protection required

• Should be part of the overall design process and integral to product design


Reduce at sourcePackaging design & optimisation

• Minor changes in packaging design• Size & shape of containers• Type and grade of material used

• Alternative on-site handling and distribution• Bulk delivery• switching from drums to returnable IBC’s

can save raw materials and landfill costs


Reduce at sourceQuestion the norm

• Plastics• Can a thinner material be used without

compromising product protection?• Can a different material be used? – checking

puncture resistance & stretch capacity• Pallets• Are there any alternatives? E.g. slip-sheets• Are they of optimum design? Lightweight for

one-trip; robust for ‘closed-loop’ systems


Case Study

• Armacell UK

• Customer & employee consultation

• Redesign

• Grant assistance


Expected benefits

• Reduced waste to landfill (own & customers)• Cost savings of £140,000 over next 5 years

• Elimination of single-trip packaging• Introduction of durable multi-trip packaging• Reduced energy consumption• Reduction in associated transport (Europe-wide)

and packaging use.• Reduction of storage space and associated

lighting


Reusing packaging

• Assess the potential to re-use existing packaging• Can it be multipurpose?• Can it be re-used on site or by another

company?• Can better handling help?


Reusing packaging

• ‘Closed Loop’ systems• Most economical• Reduce environmental impact• Effective for short transportation distances


Reuse - Design & purchase

• Simple, standard containers equal flexibility of use

• Design containers to stack or collapse where practicable

• Incorporate labelling and identification features


Recycling packagingDesign options

• Use recycled/recyclable material wherever practicable & fit for purpose

• Use a single material where possible – mixing creates difficulties

• Can labels be made of the same material as the rest of the packaging?

• Mark packaging to enable easy segregation


We don’t produce much!

• Or:• Our waste management contractor won’t

recycle our packaging waste• We operate in a remote area

• Try teaming up with other companies in the area• Communal skips• Collection rounds• Waste Brokerage


Further assistance

• Envirowise Publications

www.envirowise.gov.uk

• Design Track visit• Available to Small to Medium-Sized

companies (SMEs)


Workshop 4

Packaging Design


Workshop 5

Reducing Packaging Waste


Workshop 6

Packaging Efficiency Action Plan


Module 3 - Waste Management


Learning objectives

• Reinforce the importance of moving up the waste hierarchy

• Identify techniques to:• manage waste• improve waste disposal options


Why manage waste?

• It’s Expensive

• Legislation

• Political Agenda

• Social Agenda


Legislation

• Environmental Protection Act 1990• Duty of Care Regulations• Documentation

• Special Waste Regulations 1996 (amended)

• Segregation• Consignment notes• Notify Environment Agency


Legislation

• Waste Management Licensing Regulations 1994• Contractors• Activities performed on wastes


Legislation

• Landfill Tax (Finance Act 1996)

• Producer Responsibility Obligations (Packaging Waste) Regulations 1997

• Landfill Directive

• WEEE Directive


The Waste Hierarchy

Reduce

Re-use

Recycle

Eliminate

Treat to dispose

DisposalHow do I reach the top?


Eliminate / replace

• Elimination of waste is the best option• Reduce resource use• Reduce pollution• Use fewer resources

• Ask the following questions:• Why is there waste at all?• Does the waste really have to be produced?• Can some of it be eliminated?


Eliminate / replaceCase Study – Spray painting

• Masking tape was purchased at £15 / roll

• After review, this was found to be over specified for many applications

• Cheaper tape is now used, costing £6 / roll

• Savings are estimated at £4,500 pa


Reduce

• Can’t be eliminated, how do we reduce it?• Why is there so much of this waste?• Where does it come from?• What steps can we take to reduce it?


ReduceCase Study - Armacell

• Set a target to reduce solid waste to landfill • Reduced from 300 tonnes (in 2000) to 70

tonnes (in 2003).• Despite increase in output over last 2 yrs

• Achieved by finding an alternative use for scrap• Made crumb into a new acoustic product


Reuse

• Reusing waste within a process removes all waste disposal costs

• However, processing materials several times is expensive


Reuse Case Study - Armacall

• Target to reduce wood sent for recycling by 25%

• Implemented programme of pallet repair• Cost £3685 to set up• Reduced wood to recycling by 45% to

15 tonnes• Savings worth £9350


Reuse

• WRAP: Waste Resources Action Programme

• To develop markets and infrastructure

www.wrap.org.uk


ReuseWaste brokerage

• One persons waste is another persons raw material

• ENWORKS offer a waste brokerage service• Free• Confidential

• Websites: www.wasteworks.org.uk


Waste brokerageCase study

• Waste incontinent pads produced by one company

• Off-spec being sent to landfill

• Used by another company as spillage kits• Saved 2 tonnes of waste from landfill


Recover / recycle

• Better financially and for environment• Recycling wastes avoids payment of

landfill costs• Prices fluctuate considerably due to

instability of recycling markets• Includes many ‘hidden’ costs• Includes composting, recycling and

recovering energy from waste


Treatment

• Treating waste prior to disposal could include compaction, baling or effluent treatment

• Over £50/week on waste

• Incurs additional processing costs, however, may reduce disposal costs


Disposal

• Worst option• For the environment • Usually most expensive option• Needs careful management

• Remember true cost of waste is often 10 – 20 times that of disposal


Managing waste Skip management

• Benefits of management• Reduce costs• Reduce risks• Reduce waste


Skips

• Costs• Legislation• Skip hire/Transport/Disposal• Raw materials• Storage• Containment• Labour• Segregation• Security• Training


Collect data

• Baseline information• What skips do you have?• Who is your contractor?• Where does the waste go?• Do you have the documentation?• Who is involved?• What are the risks?


Consider your options

• Look again at the waste hierarchy

• Consider the best disposal option for each waste stream

• Always be aware of legislation


Audit

Audit waste on site:• What are the individual waste streams? • What are the quantities?• Are wastes segregated?• What is the legislation that applies to you?• How much does this cost?• Disposal• ‘True cost’


Audit

• Who is responsible for waste management?

• What training have they had?

• What mechanisms are in place to ensure that wastes are segregated and disposed of correctly?


Monitoring

• Monitor system to ensure it is working

• Collect accurate data on volumes for target setting

• Review system regularly


Waste contracts

• Regularly negotiate your contract• Frequency of lifts• Capacity• Type of Skip

- size- security- compatibility

• Are they licensed?


Summary

• A good waste management system:• Identifies opportunities • Can reduce legal risks and

environmental impact• Save money


Workshop 7

Waste Management


Workshop 8

Waste Management Action Plan


Module 4 - Water


Learning objectives

• To understand water costs

• To gain an understanding of water management

• Identify options to reduce water costs


The Water Cycle

Why focus on water?

• It can be a significant cost

• It may be an underestimated cost

• There are cost savings to be made

• Costs are increasing

• Legislation is forcing us – discharge consent

• Considerable fines for breaching this legislation

Water management

• Similar approach to energy management

• Monitoring – over time and against production

• Common areas of savings

Water billing and purchasing

• No possibility to negotiate water supply

• Check bills (meter number, meter readings, estimates, maths…)

• Key water cost components:• Water consumption• Sewerage – waste water disposal• Sewerage – surface water• Trade effluents

Are you charged correctly?

• Water not returned to sewers• Water used in production/evaporated• Grassed area• Local streams

• Rateable value• Size of meter • Fixed rate charges based on meter • Reduce size of meter


Trade effluents

• Based on a formula (Mogden)

• Ensure correct charging formula is used

• Ensure correct volumes are used

• Ensure representative samples are taken

Where is water used?

• Focus on key areas/costs

e.g. Trade effluents or domestic use

• Map water use/disposal on site

e.g. Water used as part of production, ancillary activities (cooling system)


Where do businesses use water?


Water measuring

• Calculate usage for un-metered processes• Toilets• Urinals

• Bucket and stop watch

• Flow meter

COST £££££££


Water balance

• Simple premise that what goes in must come out somewhere


Case Study JW Lees & Co (Brewers) Ltd

• Water audit and monitoring and found leaks

• Invested £400

• Immediate saving of £13,000 per annum

Water monitoring

• Monitor water costs/volume over time

• Monitor against production

Trade effluents• Contamination levels• Less contaminated effluents will be

cheaper to dispose of• Possibilities to re-use trade effluents

• Trade effluents treatments• Various technologies – filtration,

sedimentation, centrifugation• Beware of treatment costs and deposit

disposal costs• Envirowise publications

Trade effluent monitoring

0500

1,0001,500

2,0002,5003,000

3,5004,000

4,5005,000

Efflu

ent C

ost (

£)

Ct= Total Cost (£)COD Charge (£)Suspended solids charge (£)


Over-use / unnecessary use

• Working practices• Tap left running• Sinks filled unnecessarily

• Leaks• One drip per sec wastes 4 litres per day

• Over-flows


One drop/second4.8 m3/year£3 - £7/year

Drops breaking to a stream31 m3/year£18 - £48/year

3 mm stream336 m3/year£193 - £519/year

Water losses from a tap


Water controls

• Taps• Automatic shut-off or spray head taps use

about 80% less water than traditional column taps

• Level sensors (to avoid over-flows)• Pipe/tap restrictors• Hippos• Trigger guns for wash down hoses


Counter current rinsing

• If water is a big part of your process where washing is vital

Rinse CRinse D Rinse ARinse B

Work

Fresh water

drain

Water recycling

• Could you recycle water from cooling or rinsing processes?

• Could you condensate steam to re-use water?

• Could you use waste water or rain water as part of your processes?


Grey water reuse

• Water from a rinsing process

• Vehicle washing

• Kitchens


Water management summary

• Track water to control costs and legal risks

• Simple measures can lead to quick savings


Envirowise

• Free half-day FastTrack visits• smaller companies (< 250 employees)

• Free publications‘Tracking Water Use to Cut Costs’

0800 585794www.envirowise.gov.uk


Workshop 9

Assessing Water Use


Workshop 10

Water Efficiency Action Plan


Module 5 – Emissions to Air


Learning objectives

• To understand air pollution and it’s causes• To understand the legislation that

controls emissions to air • To understand the environmental and

business benefits of effective emissions management


Air emissions

• Economic case – reduce inefficiencies• Loss of raw materials e.g. solvents• Poor management

• Visible – public perception• Controlled by legislation• Licenses

• Health and safety


Emissions to atmosphere

• Gases• Carbon monoxide• Solvents

• Dust• Burning fossil fuels• Construction

• Smoke• Cars• Power stations• Furnaces


Global warming• Average increase in global temperatures• Natural mechanism - the Greenhouse Effect

• Gases form insulating blanket around Earth (carbon dioxide, methane, CFCs)

• Concentration of gases increased by human activity:• Burning fossil fuels• Vehicles• Waste – landfill• Intensive agricultural practices


Kyoto 1998

• International agreement• Legally binding targets to reduce GHG

emissions

• 20% reduction in CO2 emissions by 2010

• Climate Change Levy introduced in April 2001• Increase energy bills by 10 – 15 %


Ozone depletion

• Man-made chemicals entering the atmosphere – CFCs, halons

• React in the atmosphere and damage the ozone layer

• Montreal Protocol 1987 restricted production of ozone depleting chemicals

• Can take years for gases to have an affect


Acid rain

• Acid gases – sulphur dioxide and nitrogen dioxide• Burning fossil fuels • Motor vehicles – exhaust emissions


Smog

• Smog refers to a mixture of pollutants that form a haze over cities, particularly in summertime

• Main source of pollutants is motor vehicles

• Ozone that is formed can attack eyes, nose, throat and lungs – particularly asthma sufferers

• Weather reports now include air quality


Control of emissions

• Legislation• IPC and IPPC• Clean Air Act 1993

• Climate Change Levy

• National Air Quality Strategy

• Solvent Emissions Regulations 2004


Controls

• Integrated Pollution Prevention and Control (IPPC)

• Adopted in 1996, and will replace IPC

• Both aim to prevent or reduce emissions to air, water and land

• Includes measures to reduce waste and increase energy efficiency

• Requires investment in abatement equipment


Controls

• Best Available Technology Not Entailing Excessive Cost (BATNEEC)• IPC

• Best Available Technology (BAT)• IPPC


Managing emissions

• Managing the process• Energy efficiency• Raw materials e.g. solvents

• Managing transport


Emissions management Monitoring

• Provide information for regulators• Identify opportunities:• Reduce consumption of raw materials • Reduce emissions

• Demonstrate continuous improvement• Fulfil health and safety requirements• Improve working conditions


Monitoring techniques

• Based on material balancing • What goes in must come out

• Measurements taken:• Intermittently - sampling • Continuously - probe


Solvent management

• Solvents / VOCs

• Organic compounds - used as:• Dispersants• Cleaning agents• Viscosity modifiers• Chemical reactants


Common solvents

• Hydrocarbons (hexane, toluene, xylene)

• Alcohols (ethanol, isopropanol)

• Ketones (MEK, MIBK)


Why manage?Cost savings & public relations

• Solvents are expensive

• £500 - £2000 / tonne

• Demonstrates good overall management of risks and performance


Why manage? Environmental & health reasons

• Harmful to health (carcinogens, irritants)

• Contribute to global warming

• Can create low-level ozone (respiratory problems, irritation to ENT)


Why manage? Legislation

• PPC

• IPPC

• Solvent Emissions Regulations 2004


How to manage Step 1 – Consumption & emissions

• Gain Commitment

• Estimate:• Annual solvent cost• Cost of this consumption


Step 2 – Solvent flows


Step 3 – Calculate emissions Initial assessment

• Look at :• Inputs (purchases, recovered solvents)

• Outputs (solvent in product, water, waste, etc.)

• Stock Changes

• Emissions = I – O – S


Step 4 – Calculate costs

• Include:• Purchase costs• Costs of disposal• Costs of on-site recovery• Costs of operating LEV / abatement• Costs of process authorisation


Step 5 – Solvent management team

• Solvent Manager• Responsibilities• Accountability• Resources• Support

• Solvent management file


Step 6 – Implement savings initiatives

• Training / motivation

• Delivery (Bulk, IBCs)

• Storage (above-ground tanks)

• Distribution

• Processing (keep lids on, housekeeping)

• Cleaning (use clean solvent only for last wash)

• Recovery / Reuse


Benefits

• Reduced operating costs• Solvent purchases• Disposal costs• Compliance costs

• Increased efficiency / quality

• Improved image


Fleet management

• Road transport accounts for over 90% of passenger travel in UK• 58% of car journeys are under 5 miles and

25% are less than 2 miles• In heavy traffic jams, air quality can be 3

times worse inside the car than out• Average distances cycled & walked have

fallen by ¼ over past 20 years


Harmful effects

• Contributes to Key Issues:• Air Pollution – 70% of all carbon monoxide emissions relate

to cars• Asthma• Exhaust gases

• Climate change• Acid rain

• Resource Depletion – fuel & production• Noise Pollution• Road Building – pressure on countryside


Business & transport• What for?

• Staff• Distribution• Deliveries• Business travel

• People travelling to work account for one-fifth of all road traffic• 70% of journeys to work are by car• Traffic delays cost the UK £15billion / year• Car traffic set to increase by 22% by 2010 = 26

million registered cars


What's your position?

• How many vehicles?

• How much business related mileage?

• How much fuel consumption

• What is the potential for cost savings?


Fleet managementVehicle selection

• For each vehicle?

• What size/spec is really needed?

• What fuel type is the best option?• Petrol / diesel• LPG• Electric• Hybrid


Fleet managementVehicle selection

• Which model is best (for efficiency and CO2 emissions)? • Vauxhall Corsa 1.2 LPG• Suzuki Alto/Swift 1.1• Vauxhall Astra 1.6 LPG• Honda Civic IMA Hybrid• Vauxhall Corsa 1.0


Fleet managementDriver training

• Using best methods can reduce costs & environmental benefits:• Smooth driving (up to 10% reduction in fuel

consumption)• Correct gear selection (up to 25% saving)• Check tyre pressure regularly (under-inflated by

2ps can reduce efficiency by at least 1%)• Plan your journeys (20% of driving from being lost)


Fleet managementEncourage other methods

• Car sharing

• Public transport

• Cycling / Walking (Healthy Workplace?)


Fleet managementMonitoring & planning

• Monitor mileage and fuel use

• Identify:• Inefficient vehicles• Inefficient drivers• Fraud


Fleet managementMonitoring & planning

• Planning business trips• Is telecommunication an alternative?• Choose off-peak travel• Choose venues that will reduce travel

times for all• Can you car share?


Grants and assistance

• Powershift

• New vehicle technology fund

• Motorvate• www.transportenergy.org.uk

• CleanUp• www.cleanup.org.uk


More information• ENWORKS – 0800 032 0222

• Envirowise - 0800 585 794• www.envirowise.gov.uk• GG 203 Monitoring VOC emissions: Choosing the best options• GG 71 Cost-effective reduction of fugitive solvent emissions• GPG 218 Fuel-efficiency fleet management• GPG 314 Travel plan networks

http://www.actionenergy.org.uk/


Workshop 11

Savings in Solvents


Workshop 12

Air Emissions Efficiency Action Plan


Module 6 - Materials


Learning objectives

• Understand the impact of purchasing on resource efficiency

• Be familiar with the general principles of life cycle assessment

• Understand the benefits of cleaner design and supply chain management


Why purchasing?

• Legislative pressures• Producer Responsibility (Packaging Waste)

Regulations• Packaging (Essential Requirements)• WEEE and ELV

• Stakeholder pressure• Supply chain pressure• European policy • Sustainable development


Business benefits

• Reduce waste

• Enhance company image

• Secure supply of materials and services

• Cost saving and added value

• Create markets for new products and services


Stages in purchasing


Practical steps

• Create an environmental purchasing policy• Included in environmental policy or as stand

alone policy

• Identify alternatives• EMS (ISO 14001, BS 8555)• Labelling and information – Eco-labels


What is life cycle assessment

• Examines material, energy and waste flows of a product over its entire life-cycle

• Identifies areas of highest impact, thus allowing redesign activities to be prioritised


Stages of life cycle assessment

• Set your goal and scope• Inventory analysis• Gather data on the environmental burdens of a

product

• Impact assessment• Group environmental burdens e.g. greenhouse

gases

• Interpretation• Identify changes to product or production process


Benefits of LCA

Life-Cycle Stage Consideration

Raw Material • Use less materials

• Use materials with less impact

Manufacture • Use fewer resources

• Produce less waste / pollution

Distribution • Reduce the impact of distribution

Use • Use fewer resources

• Cause less pollution

• Optimise functionality and service

End-of-Life • Make re-use and recycling easier

• Reduce the environmental impact of disposal


Benefits of LCA

• Identification of environmental impacts – including waste

• Increased efficiency of use of resources• Raw materials • Energy

• Improved quality

• Information to back marketing claims


Life cycle assessment

• Conducting an LCA can demonstrate increased environmental awareness

• Brings business benefits

• LCA can be complex and time-consuming

• New tools and methods help to simplify this

• LCA is a platform for innovation

• Increased competitiveness


Case StudyAvad Contemporary Furniture

• Produces high-quality, bespoke furniture

• Uses reclaimed or sustainably sourced hardwoods

• Developed new jointing and production techniques, some of which use no glue or metal


• Life-cycle assessment (LCA) shows that, in the example studied, the nearest comparable techniques have almost twice the environmental impact

• Identified local sustainable timber source

• Continued research into sustainable design

• Planning marketing programme to promote cleaner products

Case StudyAvad Contemporary Furniture


Barriers and solutions to LCA

• Time and resources• Simplify boundaries• Use checklists

• Lack of expertise• Look at case studies, industry examples• Use external agencies

• Lack of data• Use the internet• Generic LCA data from Envirowise, Environment Agency


Improvements from LCA

• Change input materials• Using water based products

• Technological changes• Improving process control• Redesigning process to enable heat recovery• Improving waste segregation

• Good operating practices• Preventing unnecessary releases• Reusing materials

• Product changes


Product changes Cleaner product design

• 93% of production materials do not end up in saleable products

• 80% of products are discarded after a single use

• 99% of materials used are discarded in the first six weeks


What is clean product design?

Cleaner design is the design of a product to minimise its environmental impacts over its entire lifetime and to meet customer requirements


Benefits of cleaner design

• Lower production costs

• Improved product functionality

• Increased market share

• Improved environmental performance

• Improved customer relationships

• Compliance with legislation

• Easy disassembly for recycling

• Longer product design life (future proof)


Case Study Varian Medical Systems UK Ltd

• Manufactures sophisticated x-ray equipment for simulating radiotherapy treatment

• Identified three drivers for cleaner design• Maintaining competitive advantage

• Forthcoming legislation

• Corporate policy


Main benefits:• Cost savings of £162 000/year achieved at a cost of

£24 620

• 65% reduction in number of components used

• 29% reduction in number of fasteners

• 27% reduction in assembly time

• Elimination of glass reinforced plastic (GRP)

• Switch to water-based paints

Case Study Varian Medical Systems UK Ltd


Research the product

• Consider the product’s life-cycle

• Examine the materials used in the product

• How is the product manufactured?

• How is the product distributed?

• How is the product used?

• What happens at the end of the product’s life?

• Talk to your suppliers and customers


Consider the life cycle

• Life-cycle assessment• Aims to identify environmental impacts arising

throughout the product’s whole life

• Life-cycle thinking• Generic LCA information

• Use cleaner design checklist


Examine the materials

• Create a list of all the materials used

• Look at the environmental impacts of these materials

• Identify alternatives• Use fewer materials • Only use materials that can be recycled• Use materials containing recyclates• Obtain from more sustainable sources• Talk to suppliers/customers


Product manufacture

• Is the process energy intensive?

• Does it produce a lot of waste?

• What other resources are used? • Water

• Can resource use be reduced?


Product distribution

• What type of packaging is used?

• Could less packaging be used?

• Could re-usable packaging be used?

• How is the product stored before dispatch?

• How far are the products transported?


Product use

• Talk to consumers to find out if they have developed ‘product habits’

• Do customers feel that any components or functions are unnecessary?


End of product life

• Does the product typically go to landfill?

• Could the recycling potential be increased?• Material selection

• Stamping and labelling

• Can modules or parts be re-used?

• Service potential


Disassembly

Design priorities

Redesign

Feedback


Talk to suppliers and customers Supply chain management

• Talk to suppliers and customers • About clean design• Specification of materials• Specification of products

• Ask them to join the design team• Helps to maintain business relationships• Can share information/benefits

• Can they suggest alternatives/ideas?


BenefitsSupply chain management

• Greater control of resource flows• Raw materials• Packaging

• Reduced costs• Quicker transfer times• Fewer quality failures• Solidified business links• Increased awareness throughout supply chain• Investigating product delivery methods


Environmental management

• Environmental purchasing

• Life-cycle assessment

• Resource efficiency

• Clean product design

• All fit into an EMS structure• BS 8555• ISO 14001


Further information

Envirowise 0800 585 794www.envirowise.gov.uk

PublicationsDesign Track visit

Enworks 0800 032 0222www.enworks.com

On-site supportCase studies


Workshop 13

Clean Product Design


Workshop 14

Material Efficiency Action Plan


Resource Efficiency Training

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