UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

April 2017

Project SAP ID: 100230

Kanpur Leather Development Project (KLDP)

Technical Report: Mid Term Evaluation

Valentin Post

Consultant

Project Manager

Ivan Kral

Agro-industries and Sectoral Support Branch

This paper has not been edited

The views presented are those of the authors and are not necessarily shared by UNIDO

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TABLE OF CONTENTS

TABLE OF CONTENTS ........................................................................................................ 2

LIST OF SYMBOLS & ABBREVIATIONS ........................................................................ 3

EXECUTIVE SUMMARY ..................................................................................................... 6

1. BACKGROUND .................................................................................................................. 8

2. CURRENT SITUATION IN KANPUR / UNNAO / BANTHAR .................................. 10

3. STATUS OF PROJECT IMPLEMENTATION........................................................... 13

3.1 Introduction – the logic .................................................................................................... 13

3.2 The Kanpur Leather Development Project ....................................................................... 14

3.3 Up to date status of the Kanpur Leather Development Project ........................................ 15

4. RECOMMENDATIONS & ADJUSTED WORK PLAN .............................................. 33

4.1. Workplan as per the project document ......................................................................... 33

4.2. Recommendations ........................................................................................................ 34

4.3. Adjusted workplan ........................................................................................................ 40

5. CONCLUSIONS & WIDER RECOMMENDATIONS ................................................. 41

Annex 1 JOB DESCRIPTION .............................................................................................. 46

Annex 2: VISIT PROGRAMME .......................................................................................... 48

ANNEX 3: PILOT INNOVATION AWARD...................................................................... 50

Annex 4 DETAILS OF VISITS ............................................................................................ 53

Annex 5: PEOPLE MET ....................................................................................................... 58

Annex 6: STAKEHOLDERS MEET ................................................................................... 59

Annex 7: TRAINING ............................................................................................................. 64

Annex 8: PHOTOS ................................................................................................................ 68

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LIST OF SYMBOLS & ABBREVIATIONS

BAT Best Available Technology BCS Basic Chrome Sulphate 0Bé Baumé grades; traditional measure of liquid/solution density BOD5 5 days Biochemical Oxygen Demand oC Degree Celsius CETP Common Effluent Treatment Plant CFC Common Facility Centre CLE Council for Leather Exports CLRI Central Leather Research Institute COD Chemical Oxygen Demand CPCB Central Pollution Control Board Cr Chromium CRU Chrome Recovery Unit d Day dia Diameter DIPP Department of Industrial Policy and Promotion DS Dry Solids d.w. Dry weight € Euro (1 € = 1.06498 US$ April 2017) EIA Environmental Impact Assessment EMS Environmental Management System ETP Effluent Treatment Plant GoI Government of India h hour ha hectare (=100 m2 = 2.5 acres) HDPE High density polyethylene HP Horse power Id Indirect worker IE International Expert IISTEM International Institute of Saddlery Technology and Export Management IIUS Industrial Infrastructure Upgradation Scheme INR Indian Rupee (1 INR = US$ 0.01541, April 2017) ISO International Standards Organisation IULTCS International Union of Leather Technologists Society JTA Jajmau Tanners Association kg Kilogramme KLC Kanpur Leather Centre kWh Kilowatt hour l Litre m Metre m2 Square metre m3 Cubic metre MCI Ministry of Commerce and Industry min. Minute mm Millimetre

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mio Million MoU Memorandum of Understanding NE National Expert NG Natural Gas NGO Non-governmental Organisation NMCG National Mission for Cleaning the Ganga NLDP National Leather Development Programme NPC National Productivity Council NT Normal Temperature O&M Operation & Maintenance OSA On-line Self-Assessment Tool OSH Occupational Safety and Health p.a. Per annum pc Piece PDU Pilot Demonstration Unit PF Power Factor PFI Power Factor Improvement pH Negative logarithm of hydrogen ion concentration PPE Personal Protective Equipment PPP Public Private Partnership ROE Rate of Exchange SCP Sustainable Cleaner Production SDY Sludge Disposal Yard SME Small & Medium Enterprise S2- Sulphide SO4

2- Sulphate SPV Special Purpose Vehicle Sq.ft. square feet, equivalent to 0.929 square metres (m2) SS Suspended Solids STA Small Tanners Association SWHS Solar Water Heating System t Tonne (1,000 kg) t/d Tonne per day TDS Total Dissolved Solids TKN Total Kjeldahl Nitrogen ToR Terms of Reference TS Total Solids TSS Total Suspended Solids UNIDO UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANISATION UPLIA Uttar Pradesh Leather Industry Association UPPCB Uttar Pradesh Pollution Control Board UPSIDC Uttar Pradesh Industrial Development Corporation US $ United States Dollars (1 US$ = INR 64.6480, April 2017) VOC Volatile organic compound w/m work-month WWF World Wildlife Fund ZLD Zero Liquid Discharge

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EXECUTIVE SUMMARY

In the months of March and April 2017 the Kanpur Leather Development Project was evaluated. As it was a mid-term evaluation both timeliness of activities and deliverables were assessed, but also the quality of the deliverable, the impact and, wherever feasible, its replication. The Kanpur Leather Development Project is very well on track to meet its objective, outputs and all its deliverables. In fact, it is most likely that deliverables will exceed against targets set at the beginning of the project by a substantial margin. The installation of the core group is a strong point of the project for sharing and dissemination project related information. Particularly for all sub-outputs and deliverables under Output 1 environmental management, project targets are exceeded. Sometimes the project targets are exceeded by more than 2 times (and this whilst the project is still ongoing).

Pilot and demonstration units (PDUs) are well appreciated by the industry. Most of the PDUs are on cleaner tanning processes and renewable energy. Applying good water management in tanneries reduces water consumption by 90,000 to 250,000 l per 10 t of raw material easing effluent treatment volume. Applying all cleaner technologies: chilled or fresh hide processing, hair saving unhairing, reliming liquor recycling, proper chrome management, using correct temperature in post tanning can bring overall TDS level in the effluent to 4,000 – 5,000 mg/l from current 15,000 – 20,000 mg/l. This makes effluent treatment much easier (and cheaper!!). Smart energy management can reduce the carbon footprint of tanneries significantly. Overall reduction in energy consumption in the tannery by application of solar energy (hot water / hot air) is around 15% (this includes energy from all sources (electricity, diesel, coal) and all processes including primary and secondary treatment of effluent). Savings of CO2 emissions are in the order of 100s of tonnes per year per factory. Occupational Safety and Health (OSH) measures are practically non-existent, especially in the smaller traditional tanneries. The project is rightly taken actions in this regard by demonstrating safety equipment, audits etc. No records are being kept of work related illnesses and causalities, yet the project clearly aims to reduce this significantly, particularly through awareness raising and training on the highly toxic H2S gas coupled with distribution and explanation of handheld H2S meters. For Output 2, solid waste management, several tracks are being pursued. The baseline data collection process focuses on generates, yet it is recommended to include collection and existing conversion and disposal as well. Strong point for all solid waste management activities is the existence of safe landfill site(s) with sufficient capacity. In time, some of the current solid waste conversion practices are unlikely to continue. Therefore, the Kanpur Leather Development Project correctly investigates some of the latest technologies in converting of tannery solid waste.

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The project has a strong focus on training with clear target groups, owners and technicians of tanneries. Being all adults they are voluntary learners. Adults learn best when the context of the training is relevant to their own lives and experiences. And when they are actively involved. Conventional training is not a very effective methodology for training adults as it ignores the integral role that adults play in their own learning process. UNIDO used a variety of training methodologies. These training methodologies had a high degree of practicals and were thus very well suited to the audience of adult learners. 733 people have been trained in on-the-job training, workshops, seminars, conference etc. This exceeds the target of 300 by far, whilst the project is still going on. The Kanpur Leather Development Project is in line with Government policies and objectives. The Project is also below the radar screen, which on the one hand safeguards it from any possible controversies, yet on the other hand hampers it in getting its results known to the outside world. Despite this replication is already taking place without technology package being ready as data collection is still ongoing. It is expected that the industry will invest up to US$ 2.5 Million against the US$ 1 Million from the Government. Several actions were suggested to either improve the likelihood of the replication, its wider applicability or to improve the quality of the activity and corresponding deliverable. These were discussed with the project team and wherever deemed feasible adjustments were made in the workplans. As the project is non-controversial and has results, it is recommended that a more active publicity will be sought in collaboration with KLC and CLE. Some adjustments in the project have also been discussed and agreed upon including cost benefit analysis (CBA) of pilot demonstration units in Rupee (INR) terms. Innovation Award as pilot to go national (CLE) and the Award for different categories. Pilot shop floor training for workers to maximize environmental impacts, e.g. of the use of water meters and other cleaner practices. Increase the number of PDUs through introducing two new PDUs for solid waste conversion, i.e. composting of tannery solid waste and PDU on tallow manufacturing. For occupational safety and health start the demonstration at small tanneries at the earliest and commence the collection of accident data. In view to remain abreast of the best available technologies globally and the tremendous amount of goodwill created by the Kanpur Leather Development Project, it is recommended that the Government of India and UNIDO consider a successor project with roughly the following contours.

The focus should be on the circular economy with advanced improvements in the carbon and water footprints of the industry keeping in mind the different technology levels of industry, vide small and medium / large. Key interventions will be in safe reuse waste – possibly in combination with municipal waste - and reduction in the quantity and pollution load of waste water.

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1. BACKGROUND

Kanpur/Unnao leather development project will address sustainability and minimization of waste at source, cleaner tanning technologies in tanning sector, improving efficiency of effluent treatment plants, preparation a road map, bankable feasibility studies for common facility centers for leather production, common waste management facilities and productivity and quality improvement, which leads to improved performance of the companies and business linkages. At the same time, the ultimate objective of the proposed UNIDO Programme, taking into account the developmental responsibility within the framework of its mandate, is to improve employment possibilities for people in the regions where the targeted leather-clusters is located. Therefore, the Programme contributes actively to the enhancement of the performance of local SMEs to ensure their sustainable inclusion in domestic as well as international supply chains. As a result, the leather clusters will benefit from stronger backward linkages with a pool of local component suppliers, thus, increasing the overall impact of the Programme in terms of expanding and sustaining higher levels of employment, production, and exports, which will eventually contribute to income generation and sustained overall development. The overall objective of the Kanpur Leather Development Project (KLDP) is to enable local leather-based industry to sustain conversion of locally available raw hides and skins into exportable products, either directly as genuine leather or as derived finished product (e.g. footwear), thereby providing employment and income opportunities for the increasing population without jeopardizing the livelihood of the human settlements through environmental degradation threatening their rapidly depleting water sources and agricultural land. The following are the specific objectives of the project:

Environment sustainability & improved efficiency and best practices in leather processing

Waste Management

The current assignment is specifically to:

a) Review all project related documents, more specifically in the Kanpur / Unnao area project achievements, compare with the work-plan and project document, activities. This should form part of a summary mid-term evaluation.

The corresponding result should be an up to date status on the project implementation (Chapter 3). Most important details of visit and interactions are attached as Annex 3.

b) Assistance with adjustment of the work-plan and activities based on the findings with special focus on safety for small tanneries, Innovation Award and solid waste.

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Preparation of recommendations for such actions if needed ToRs etc. The corresponding result should be recommendations and adjusted work-plan

c) Presentation of findings and results of evaluation to the stakeholders. The minutes of the meeting are attached as Annex 4.

The corresponding result should be the project mid-term evaluation

d) Preparation of the technical report (midterm evaluation).

The corresponding result should be the technical report of the mid-term evaluation.

The Technical Report comprises an Introduction (Chapter 1). Chapter 2 gives a short outline of current situation of tanneries in and around Kanpur. Chapter 3 give the up to date status of the Kanpur Leather Development Project. Recommendation for further project improvement and timelines is in Chapter 4. Chapter 5 gives conclusions and recommendations. The Full Terms of Reference are attached as Annex 1. The detailed visit programme is attached as Annex 2. The revised Tannery Innovation Award is in Annex 3. Some details of visits and interaction are in Annex 4. Some of the people met is in Annex 5. Minutes of the meeting of the stakeholder’s presentation is in Annex 6. The theory behind adult learning is in Annex 7. Finally some photos are in Annex 8.

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2. CURRENT SITUATION IN KANPUR / UNNAO / BANTHAR

There are several tannery clusters in and around Kanpur, see map below.

The environmental situation in Kanpur has come under increased public and Government scrutiny. Post the State elections in Uttar Pradesh, it now has the same Government at the Centre and in the State (BJP). Several relevant articles appeared in English dailies in the two weeks that I was in Kanpur. The first article concerned the raw material supply (Article 1).

The National Mission for a Clean Ganga (NMCG) has been converted into an implementation authority with full implementation powers. It is set up along the lines of a Ministry (central, state, district) etc. and has several committees working for it.

Apparently, a contract has been given to CLRI to identify proper environmental solutions for the tanneries, particularly concerning waste water treatment. The zero liquid discharge is specifically mentioned as an option yet at the same time relocation of Jajmau tanneries specifically is being discussed too (Article 2). As per the latest information zero liquid discharge is the option of choice (Article 3).

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Article 1: Slaughterhouses closing down

A couple of days later the following article appeared (initially only in Hindi press adding to uncertainty). Article 2: Relocation of Kanpur tanneries

On the 8th of April, the following headline appeared. Whether it will be relocation or zero liquid discharge – the two major options that are currently under review - a sense of urgency was omnipresent.

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Article 3: Zero Liquid discharge

Whatever option is going to be decided upon, cleaner production processes, occupational safety and health and solid waste management as currently practiced show environmental and safety gains that can be made by the industry. This realisation coupled with increasing environmental awareness by many within the industry, external pressures (Government, buyers and to a lesser extent the public) are external factors that could explain part of the achievements of the project under review.

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3. STATUS OF PROJECT IMPLEMENTATION

3.1 Introduction – the logic

The detailed observations from the visits are attached as Annex 4. This Section follows the structure and logic of the Project Document. The logic underlying the project is that

(a) cleaner tanning and occupational safety activities require a level of knowledge and understanding before results can be achieved. Therefore, the project has a very strong emphasis on training and learning using modern tools such as e-learning, on line self-assessment and certification, and;

(b) seeing is believing, many of the cleaner technologies having significant environment savings in terms of lower water and carbon footprints need to be seen before the industry is willing to replicate. Therefore, in cleaner processes, occupational safety and health and solid waste management emphasis is laid on visible demonstration at factory scale through pilot demonstration units.

(c) In the case of solid waste management, with the solid waste emanating form the tanneries a comprehensive overview of the situation in and around Kanpur is currently absent. Therefore, a baseline needs to be established first. Also, there are several solid waste conversion technologies that are emerging and it is of great interest of these can be brought under the attention of the stakeholders in and around Kanpur.

Waste management globally prefers reduce before reuse and as a third recycling. If all these are not possible than safe disposal is the last and final option. Reduce is preferred but often the most complicated as it is built upon changed production processes and /or changed behaviours. The figure below gives an overview.

Changes in production processes and behaviour change are both pursued, in terms of lower water (meters, changes in processes) and carbon (application of solar, energy saving in machines etc.) footprints.

Reuse is typical for lime or wet blue splits. In the clusters in Kanpur reuse is predominantly in wet blue splits. The project has introduced the reuse of recovered hair and to a certain extent salt.

Partially treated waste water is recycled and many solid wastes are recycled too, some with safe processes and products whilst others are suspect on one or the other count or both

Disposal: sludge from treatment plants

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Changes in behaviour require first and foremost awareness raising. Several workshops organised by different technical / supporting agencies including UNIDO, CLRI, CLE, KLC, Solidaridad and industry associations (UPLIA, JTA, STA) have put this firmly on the agenda. Several Government agencies (UPPCB, CPCB, DIPP, NMCG etc.) are pursuing the same from a different angle. Changes in production processes require a much more in depth knowledge of the industrial processes in tanning and therefore only few are actively pursuing this, notably CLRI and UNIDO. UNIDO is pursuing the above (reduce, reuse, recycle) in the Kanpur leather sector through the Kanpur Leather Development Project.

3.2 The Kanpur Leather Development Project

The Project Objective is: To enable local leather-based industry to sustain conversion of locally available raw hides and skins into exportable products, either directly as genuine leather or as derived finished product (e.g. footwear), thereby providing employment and income opportunities for the increasing population without jeopardizing the livelihood of the human settlements through environmental degradation threatening their rapidly depleting water sources and agricultural land. To achieve the objective, two outputs and several activities with deliverables are defined. These are: Output 1: Environment Sustainability The objective of this output is the: Introduction and continuous adoption of a set of cleaner and more energy efficient technologies Activities under the output are: 1.1. Development of modern learning material for sustainable & cleaner processing in the

leather sector 1.2. Introduction and support of the Awarding system for the Leather Company of the Year to

promote best practices 1.3. Training of trainers and trainees using new learning modules 1.4. Practical training – preparation of a set of specific recommendations on leather

processing technology resulting in a significantly lower pollution load, carbon and water footprint, pilot trials in selected tanneries, guidelines for implementation in different production conditions, demonstration of achievements and dissemination of techno-economic information.

1.5. Best practices and sustainable production – pilot implementation of audits in selected tannery

1.6. Implementation of occupational safety and health (OSH) measures in tanneries, demonstration of applications and dissemination of related information.

1.7. Screening of technologies for reduction of sludge production and generation 1.8. Practical training on technologies reducing the pollution load will help companies to

evaluate technologies and provide recommendations on commercial scale application. 1.9. All other activities will be supplementing the scheme.

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Output 2: Waste management The objective of this output is: economically viable options, implemented by members of tannery associations, possibly with international joint ventures. Technologies: Glue from raw trimmings and limed splits; Animal feed from limed fleshing; Leather board from chrome shavings and vegetable tanned material. Activities under the output are: 2.1. Preparation of baseline data and assessment of waste generation within Kanpur based

tanneries and leather products producers including mapping of the whole waste cycle 2.2. Preparation of overall concept/blue print for the waste management for Kanpur based

industries 2.3. Waste minimization and better use of raw material in footwear and leather products

industry 2.4. Preparation of feasibility study for waste management in tanneries covering all fractions

of wastes and elaborating various possible options for utilization. 2.5. The comprehensive plan for Kanpur based tanneries is aimed at long term solution for

solid waste

3.3 Up to date status of the Kanpur Leather Development Project

As most project activities had one or more deliverables, the status of project was measured against these deliverables in terms of:

(i) timeliness, i.e. where the activities done in a timely manner, and (ii) did the activities have the desired results or were the deliverables met.

The many activities and twenty (20!) deliverables necessitated a visual approach for the presentation of the findings to the stakeholders form the industry. This part of the technical report is the description of the project status as per the presentation. Activity 1.1: Development of modern learning material for sustainable & cleaner processing in the leather sector. It has one deliverable: On Line course “Sustainable & Cleaner Leather Processing This deliverable comprises 5 Modules. It is well under way with 1 module fully on-line, another one ready to be put on line and for the other three most of the back-ended technical work is completed. There are some issues with registration and these have been brought under the attention of the partners dealing with this. In addition to this, more material is made available on line.

1. How to deal with H2S gas in tanneries and ETPs 2. First aid in the workplace 3. Introduction to treatment of tannery effluent

Two more online courses are in the request for quotation stage, vide: Physical and chemical testing of leather Analysis of tannery wastewater

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Therefore, the visual presentation is as Graph 1, clearly showing that under this activity actual results was much more than presented in the project document, viz. four instead of one deliverable with two additional deliverables in progress. Graph 1: Status of Activity 1.1

Activity 1.2 Introduction and support of the Awarding system for the Leather Company of the Year to promote best practices. It has one deliverable: Tannery and ETP Kanpur Award The project Supported Kings International tannery to obtain the “Tannery of the Year – Asia” award by Leather International. In consultation with industry stakeholders and to get maximum exposure, the activity has been modified. The Innovation award has been relaunched with CLE & KLC and now comprises two categories, small tanneries (loosely defined as raw to semi-finished leather) and large tanneries, (loosely defined as raw to finished leather). The visual presentation is as per Graph 2. The activity is in progress. It has the potential to go national post 2017. Graph 2: Status of Activity 1.2

1.1. Development of modern learning material for sustainable & cleaner processing

Exceed

expectations

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expectations

As expected / planned

Starting point0

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Deliverable on Line

course “Sustainable

& Cleaner Leather

Processing

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Tannery and ETP

Kanpur Award

Supported Kings

International tannery,

obtained “Tannery of the

Year – Asia” award by

Leather International

Relaunch innovation

award with CLE & KLC

Expected to meet target by August 2017

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Activity 1.3 Training of trainers and trainees using new learning modules has – for practical and presentation reasons - been combined with Activity 1.8 Practical training on technologies reducing the pollution load will help companies to evaluate technologies and provide recommendations on commercial scale application. It has two deliverables: Training of Trainers Report and Training reports (at least 300 managers/technicians directly trained) Firstly, the targets both on terms of number of reports and number of trainees have been exceeded, in fact for trainees more than doubled (733!). Secondly, the variation of training methods used has been very suitable for the adult brains (for more details please refer to Annex 6, adult learning). The Project used a staggered structure of training and a variety of training methodologies. This is outlined in the drawing below.

1. International experts (IE) on short mission worked on the job with national experts (NE)

2. IE and NE worked in the various tanneries with the leather technologist, electrical or mechanical maintenance persons, or those in charge for OSH as well as management. These were direct practical training.

3. IE, NE and the leather technologist, electrical or mechanical maintenance persons, or those in charge for OSH. Made trial runs quite often in cleaner production processes (hair saving etc.) but also in energy or OSH. The skills imparted by the IE to the NE were further tested practically when the NE were together with the responsible factory persons putting the activities further into practice. This can be described as participatory practical training with many reflection moments.

Additionally, 4. Factory floor demonstrations for instance in the case of hairsaving and occupational

safety and health (OSH) these were given in the tannery premises themselves. 5. Several workshops were held. Invariable at the end of their mission IE would present

their findings in workshop often attended by 30 –40 sometimes more participants. NE themselves would also convene workshops. Participants were tannery staff,

International Expert National Experts / trainers

Tannery leather technologist, OSH, engineer in charge, management

1

2

2 2

Practical trials

3

3

3

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sometimes owners and members of the various counterpart organisation KLC, UPLIA, STA, JTA etc.

The visual presentation is as per Graph 3. UNIDO used a variety of training methodologies. These training methodologies had a high degree of practicals and were thus very well suited to the audience of adult learners. In terms of depth and width of training subjects, deliverable has already been exceeded, the number of 300 trainees has been exceeded nearly 2 ½ times, at present 733. Even so, still more training is planned including shop floor training.

Graph 3: Status of Activity 1.3

Activity 1.4 Practical training – preparation of a set of specific recommendations on leather processing technology resulting in a significantly lower pollution load, carbon and water footprint, pilot trials in selected tanneries, guidelines for implementation in different production conditions, demonstration of achievements and dissemination of techno-economic information. It has eight (8 !) deliverables: PDU 1 – Hair Saving Liming (reduction of sludge generation) PDU 2 – Water management/control PDU 3 – Energy – Solar Water Heating System D4 Documentation of tests and trials D5 Technology Package – Hair saving system D6 Technology Package – Energy – Solar Water Heating System for tanneries D7 Technology Package – Enhanced chrome tanning system D8 Technology Package – Water management and water conservation

PDU stands for Pilot Demonstration Unit. During the first 15 months of the Kanpur Leather Development Project, in response to new environmental insights with the industry and close collaboration with its trade organisations, the number of PDUs was increased to eight.

1.3 Training of trainers and trainees

Exceed

expectations

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Deliverable: Report –

Training of Trainers

Training reports (at least 300

managers/technicians directly

trained)

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PDU 1 – Hair Saving Liming (reduction of sludge generation) D5 Technology Package – Hair saving system

The amount of hair saved increases with time, but there is an optimum as prolonging the process time may damage the grain. The data from KINGs has been compared with international data (reference Willy Frenddrup’s Hairsave unhairing available at LeatherPanel.org).

The achievable savings in pollution load are given below. These are significant though will vary per type of animal. Table: Reduction on pollution load from hair save unhairing (Ref. Willy Frendrup)

Suspended solids being major issues in effluent treatment. As per the same report significant environmental impact can be achieved with hair save unhairing.

Photo: far left hair save unhairing machine at Kings Photo left: hair used in aquaponics Figure below: process time versus amount of hair removed

Graph: origin of suspended

solids (source W. Frendrup)

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Results at Kings are quite encouraging as Graph below shows.

That hair save unhairing has very positive implications is evident, yet for many years the question has been, what to do with the hair. Kings Tannery International has found an interesting solution, see pictures below and the arrangement they have made with a nursery that delivers plants and takes back excess hair. Under the Kanpur leather Development Project following activities have been scheduled: Monitoring at KINGs and Technology Package preparation (Deliverable 5). PDU 2 water management/control at 6 tanneries It has another deliverable (D8) Technology Package – Water management and water conservation. So far the following has been achieved. (a) Four small tanneries - water flow meters (Makhdoom Industries; Tej Industries; Finished Leather Jobwork Industries; Decent Leather Finishers) (b) electromagnetic flow meter with batch control (AKI India (Magarwara)) (c) Automatic water addition cum mixing systems (Leayan Global (Unnao))

This choice is based on the sophistication of the tannery (water flow meters in four traditional small tanneries) and on testing in the more organised local industry two different types of more sophisticated water control systems.

Photo: Water meters at Tej Industries

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Results so far have been impressive mainly in the more organised tanneries • 20% reduction in overall water consumption! • 15% COD & 10% TDS reduction achieved in post tanning operations • Consistency in quality from batch to batch • Chemical savings

PDU 3 – Energy – Solar Water Heating System at Super Tannery has also its own Technology Package – Energy – Solar Water Heating System for tanneries (D6).

A solar water heating system has been installed at Super tannery Jajmau. The surface area covered is 192 m2. The hot water generated is used in post tanning operations: retanning, fat liquoring, dyeing.

Photo: rooftop area at Super tannery Photo: control panel

Photo: Electromagnetic flow meter with batch control (AKI)

Photo: Automatic water addition cum mixing systems (Leayan Global)

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At this point in time only the expected performance can be provided as the monitoring has just started.

• Expected generation of hot water: 36 l /m2 • Coal saving 48 t/ yr • CO2 emission reduction: 125 t CO2 /yr • COD reduction 17% and TDS reduction 13% in post tanning operations • 17% saving overall energy consumption (coal, electricity, diesel) including primary,

secondary treatment effluent UNIDO is already planning to continue monitoring at Super tannery. It also plans to monitoring the results of expansion of the solar system at Super tannery (installed at Super tannery own cost). Also the technology package is under preparation.

PDU4: Solar air heating system at Calico Impex It covers an area of 270 m2. The hot air is connected to the drying tunnels of two autosprays (alternate use). Presently it is being tested if the surface area of 270 m2 will be sufficient for two drying tunnels in peak summer.

Photo: Hot water tank & heat exchange

Photos: Left Rooftop area at Calico Impex Left bottom: copy of hourly monitoring sheet Photo below: drying tunnnels

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The monitoring is ongoing. As per current findings: Savings in energy 14% of overall energy consumption (coal, electricity, diesel) including primary, secondary treatment effluent. This also implies a CO2 reduction: 133 t CO2 / y The Figure below shows that steam addition is very limited during the warmest hours of the day. In fact, more recent data is even better. For some hours, no steam needs to be added at all.

PDU5: Processing chilled hides at AKI Tannery This is potentially one of the most important demonstrations. The key issue in waste water treatment from tanneries is the high level of salts. A significant part of this salt comes from the way hides and skins are preserved, i.e. by the use of salt. Industry representatives do recognize the significance and the potential, 40% of slaughter in India takes place in a radius of 300 km from Kanpur. At the same time they point out many difficulties, widespread slaughter of few animals at a time, difficulties in grading and selection next to a well-established raw hide and skin trading system. Another point raised by them is the higher cost of chilled hides as compared to wet salted. Even without taking the cost of effluent treatment into account, the project has calculated the electricity cost at 15 days (max.) as INR 800 /t (refrigerated container), whereas the salt cost at 15 days (max. storage time is 45 days) as INR 900/t. Shortening the period of chilling reduces the cost further, whereas it does not alter the cost of perseveration using salt. Several stakeholders even suggested the possibility of processing fresh hides.

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AKI tannery did not find any issues with processing of chilled hides, yet they did find some issues in grading. Environmental impacts are significant with a reduction of TDS in the effluent by 40%. The reduction in salt use is min. 300 kg/t. The project will monitor further trials in different conditions vide peak summer and monsoon. PDU 6: Desalting at Kings Processing chilled or fresh hides is superior from an environmental point of view, even in the best of circumstances it will take time before this becomes common practice. Therefore, there is a need for desalting. Using modern desalting vessels (photo) the dusted salt recovery is 60 to 90 kg/t raw material. The corresponding overall TDS reduction in the effluent is 15-20%. Not all tanneries can afford or have the space for the dedusting vessel, hence the project will start collecting data on salt removal using a brush (Super tannery).

PDU7: Lime liquor recycling at Kings In this PDU relime liquor is recovered to the tune of 80% out of a 125% float. This reduces overall water consumption by 800 l/t and it saves lime by 15-25%. Under the project monitoring is ongoing.

Photo: Dedusting vessel at Kings International

Photo: Relime liquor recycling at Kings International

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PDU8: Water control in fleshing machine This idea was derived from the machine in AKI (photo of fleshing machine below), an order has been placed with a local equipment manufacturer for construction of similar devices in function (photo below) whereby a sensor stops water supply if hide is turned and the blade of the fleshing machine is idling. Water saving 1 to 2 m3 /t of raw material. These devices will be installed in smaller tanneries (members of STA) vide: Crown Tanning Industries; Shahid Tannery; Tej Tanning Industries; Triveni Tannery; Irfan Tanners

In view of the many additional pilot and demonstration units and the continued data collection required for the technology packages the entire activity is much wider in scope and expected impact than as envisaged in the project document. This is presented graphically in Figure 4 below. Graph 4: Status of Activity 1.4

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Photos: Below: fleshing machine at AKI Right: device with sensor and by pass as it will be installed at selected small tanneries

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Activity 1.5. Best practices and sustainable production – pilot implementation of audits in selected tannery (technically capable volunteer tannery nominated by DIPP or leather association) – environmental audit and improvement organized by the Leather Working Group and Energy Controlled Leather or similar applicable within Kanpur cluster in cooperation with relevant institute. This activity has two deliverables vide: Documentation audits and corrective actions and new modern On-line Self-Assessment tool for tanneries/companies What has been completed so far is as per the list below:

• Energy & carbon footprint assessment 6 tanneries • Benchmark Best Energy Efficiency calculated in range of -37.2% to +4.4 %. Though this

implies that tanneries in the Kanpur area are quite energy efficient (a negatives value means being more energy efficient, a large part of this can be attribute to the fact that due to climatological aspect, tanneries do not use heating)

• The energy footprint ranges from 29 – 53.4 MJ/m² of finished leather • Also for 2 tanneries a comprehensive energy audit was conducted • In a workshop 27 Energy conservation measures (see Tables below)

Table: energy saving measures

Equipment / systemEnergy saving

Cost saving

CO2

emission reduction

Motors (energy class, V belts, maintenance) √ √ √

Voltage stabilisers √

Contract optimization √

OLTC on HT transformer √

Automatic power factor control √

Optimimum size of generators √ √ √

Electrical load optimization √ √ √

Change of old generators √ √ √

Cogeneration (combined heat and power) √ √ √

Trigeneration (combined cooling, heating and power) √ √ √

Production running time optimization √ √ √

Light bulbs replacement with LED, automatic sensors √ √ √

Fans (regulation, eco-ventilation, automatic sensors) √ √ √

Air condition and air cooler systems √ √ √

Cooling tower (fan control by temperature, replace Al fan blades),Remark: prevention of legionella danger

√ √ √

Aircompressor (leak arrest, heat exchanger, pressure optimization) √ √ √

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Table: energy saving measures continued Additionally, awareness raising activities had been held on international certification (environmental management systems) The on-line self-assessment is available and data can easily be filled in, vide “tannery of the future”. In-depth training on Leather Working Group (LWG) Environmental Stewardship Certification has been conducted. (In Annex 4 is a short reflection on the discussion that was being held at Super Tannery with some of the buyers). All of the above has resulted in an energy investment by 3 tanneries of about US$ 20,000 Additionally, a pre-audit for LWG certifications in selected tanneries has been scheduled for June / July 2017. Due to the many additional actions undertaken, the investments already undertaken by the industry during the project, the entire activity is much wider in scope and expected impact than as envisaged in the project document. This is presented graphically in Figure 5 below. Graph 5: Status of Activity 1.5

Equipment / systemEnergy saving

Cost saving

CO2

emission reduction

Water heater / steam boiler: economiser √ √ √

Water heater / steam boiler: use of thermic oil heater √ √ √

Heat exchanger (maintenance / fouling) √ √ √

Steam / hotwater tank + pipeline insulations, closed tanks √ √ √

Drying tunnels: heat recovery systems √ √ √

Drying tunnels: energy controlled systems √ √ √

Toggle drier: plastic curtains for in/out openings √ √ √

Solar photovoltaic system for electricity (during powercut still needgenerator), system efficiency only 10-20%

√ √

Photovoltaic thermal hybrid system (PVT) for electricity + hotwateror hot air supply

√ √ √

Solar thermic oil system (direct dryer heating / thermal oil boiler) √ √

Solar hot water system (dryer heating / boiler supply) √ √

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Activity 1.6: Implementation of occupational safety and health (OSH) measures in tanneries, demonstration of applications and dissemination of related information. This activity has multiple deliverables vide: PDU – Safety measures (appropriate chemical storage to avoid contamination) PDU Selected units e.g. safety barriers etc. PDU Use of alarms for Hydrogen Sulphide Formation (main risk of fatal accidents in tanneries and CETPs) D11 Documentation - audits and corrective actions D12 New modern On-line Safety Self-Assessment tool for tanneries/companies

Occupational Safety and Health (OSH) standards - not surprisingly – vary tremendously. At the bottom end are tanneries where information about harmful substances via material data sheets is rare. PPE is sometimes not existing or not used by the worker also not during harmful process steps! Many machines, including drums, have no sufficient protection concerning their moving parts! Instructions on machines are not in local language, people have no knowledge about IP55 degree protection. Fire-fighting equipment and first aid kit exist, but are placed at wrong places and expiry dates are not checked. Neither do incident records exist. At the top end, there are tanneries with good visible OSH practices, such as Kings International (Photo). Due to the project Kings has also improved in chemical storage. On its own it has installed safety guards. The challenge is to bring the less organised tanneries closer, if not up, to the level of the best practices. The project has rightly selected some smaller tanneries of the small tanner’s association (STA) to demonstrate improved OSH practices for the chemical store (currently very disorganised see Photo). These are: Tej, KC Tan, Decent, Vertex, and Irfan. Furthermore, also in Tej, the PDU on safety barriers will be done, this is yet to start.

Photo right: Tej chemical stores prior to OSH activities Photo below: Kings International note yellow safety guard

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PDU Use of alarms H2S H2S meters have been distributed to Jajmau, and Banthar CETPs including onsite demonstration and training on use. Portable H2S meter has been handed out to the CETP Unnao during my visit including instructions on how to use it. A portable H2S meter has been handed out to the STA (as per their records it has not really been used yet). Some more organised tanneries have requested for the address of the distributor and are likely to purchase these directly. For more information, please refer to Annex 4. The project has translated the H2S booklet in vernacular (Hindi). This makes it more accessible for the workers in the tanneries.

D11 Documentation - audits and corrective actions. Safety audits have been completed in Tej and Rukhs D12 New modern On-line Safety Self-Assessment tool for tanneries/companies. There is a H2S on line course as well as the theoretical part of the First Aid course is available on line. For practicals, a contract has been entered with St Johns Ambulance. Lastly, Section 9 of “Tannery of the future” contains on line self-assessment. This may need to be expanded. Generally speaking and barring some exceptions, OSH does not come close to international standards. The Kanpur Leather Development Project goes a long way in making this very clear and visible and does show the importance of OSH through pilot and demonstration units and is on track to meet all its deliverables as the Graph 6 below shows. Graph 6: Status of Activity 1.6

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It should be emphasised that even when the Kanpur leather Development Project meets all its deliverables during this year, a significant improvement in OSH practices in tanneries in Kanpur – particularly the smaller ones - is unlikely as it is beyond the scope of the current project. Activity 1.7 Screening of technologies for reduction of sludge production and generation With its deliverable, a report/study – scope for reduction of sludge production and generation & comparison ZLD & non ZLD technologies Activity 1.9 Similarly all other activities will be supplementing the scheme with its deliverable Report for the IULTCS Congress – especially related to achievements in India During the IULTCS Congress in Chennai 2017 the following report was presented: Analysis of flow, energy and carbon footprint aspects of Zero Liquid Discharge (ZLD) technology J. Buljan, K.V. Emmanuel, M. Viswanathan, M. Bosnić, I. Kráľ, XXXIV IULTCS Congress, Chennai, 2017 Recommendation on improvement ETP has been given as one of the supporting activities. Sludge production and generation can be reduced through hairsaving technology (PDU 1), data has been collected and extrapolated on this. Interestingly the tannery has identified a use for the nitrogen present in the hair (aquaponics and nursery). This is further elaborated in the recommendations for immediate project improvement (Section 4.2). India is the already No 1 user of UNIDO’s LeatherPanel.org, vide over 7,000 sessions with 5,700 downloads. The activity is on track to meet all its deliverables as the Graph 7 below shows. Graph 7: Status of Activity 1.7

Output 2 has five activities (see above).

Activity 2.1 Preparation of baseline data and assessment of waste generation within Kanpur based tanneries and leather products producers, including mapping of the whole waste cycle – collection – transport – reusing – disposal and regulatory framework with its deliverable Solid wastes – baseline report

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comparison ZLD & non

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& UNIDO) Report for the

IULTCS

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Activity 2.2 is the preparation of overall concept/blue print for the waste management for Kanpur based industries. With the report of Mr. Milos Straka, this activity has been completed. Activity 2.3 Waste minimization and better use of raw material in footwear and leather products industry with its deliverable Solid wastes – baseline report So far data collection has been completed in 15 tanneries, it is still ongoing in 5 tanneries. Currently solid waste generated in the tanning processes is segregated and collected. It is recommended to present this as a flow diagramme. For more recommendation please refer to Section 4.2. Waste minimization and better use of raw material is a s of yet not really part of the study, yet in practice some integrated units (vide tannery and footwear or leather goods) have seriously considered waste minimization. The activity is on track to meet its deliverables as the Graph 8 below shows. Graph 8: Status of Activity 2.1, 2.2 & 2.3

Activity 2.4 Preparation of feasibility study for waste management in tanneries covering all fractions of wastes and elaborating various possible options for utilization with its deliverable: Feasibility study for utilization of Solid Wastes in Kanpur/Unnao Activity 2.5 Comprehensive plan for Kanpur based tanneries is aimed at long term solution for solid waste with its deliverables: Bankable proposal for main fraction (tallow recovery), including technical specification and Technical package – Tallow recovery with techno-economic details for replication Several sub-activities are being pursued at present: Fleshings conversion into biogas – evaluation of German technology ongoing

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Tallow recovery ongoing, possible PDU on local technology at AKI Fleshings conversion into poultry feed - evaluation in progress Improved tannery design as a template in process & presentation scheduled For more details, also refer to Section 4.2 and Annex 4. The overall comprehensive plan is scheduled to be presented to the stakeholders by the end of October 2017

The activity is on track to meet its deliverables as the Graph 9 below shows. Graph 9: Status of Activity 2.4 & 2.5

2.4 & 2.5: Waste management

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4. RECOMMENDATIONS & ADJUSTED WORK PLAN

4.1. Workplan as per the project document

The workplan as per the project document of the Kanpur Leather Development Project is as below. Deviations from the workplan are few, the major one is related to Output 1.1 as this was caused be delay in receiving payment to pay contractors, it has been adjusted internally.

The following activities were already planned: • OSH pilot demonstration units – 3 tanneries in Small Tanners Association • Fleshing machine water control device – 5 tanneries STA • First aid training by St. Johns Ambulance Association with practical • Demonstration of brush type desalting machine, evaluation and comparison with

other desalting mechanisms • Study tour – Turkey (waste management through better designed leather complexes)

and Germany (biomethanation of fleshings, tallow recovery, etc. • Template tannery design for a tannery to process 1000 pieces per day • Mr. Patrick Zerhusen, Intern. Expert – Cleaner Technologies July 2017 • Innovation award • Baseline data on solid waste • Feasibility studies on solid waste conversion • PDU on-site demonstration events • Workshops

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4.2. Recommendations

Based on the mid-term evaluation and discussion with key stakeholders it is recommended to make the following adjustments:

1) Provide cost benefit analysis (CBA) of pilot demonstration units in Rupee (INR) terms. 2) Innovation Award as pilot to go national (CLE) and the Award for different categories –

include study tour Tamilnadu 3) Install a few more water meters at members of the small tanners’ association 4) Pilot shop floor training for workers to maximize environmental impacts, e.g. of the

use of water meters and other cleaner practices. 5) Present data of PDUs in different formats for different audiences; for industry in terms

of INR (CBA); for Government replication, environmental impacts and industry investments (flyers). In case of chilled hides videos.

6) For sludge reduction refocus on hairsaving 7) Modify solid waste data collection to gather data on who collects it and at what price

and where does it go to, baseline to contain flow charts 8) Expedite market survey tallow post technical feasibility and basic financial-economic

feasibility 9) Assist regular solid waste conversion units in preparing DPRs for the Government to

increase safe conversion of tannery solid waste into products. 10) Increase the number of PDUs! Particularly through introducing two new PDUs for solid

waste conversion, i.e. composting of tannery solid waste and PDU on tallow manufacturing.

11) For occupational safety and health start the demonstration at small tanneries at the earliest and commence the collection of accident data.

Ad 1) As an example of how the cost benefit analysis in INR terms can be worked out: the case of PDU 1 – hair saving. On the cost side: provide investment1 in INR, but also additional expenses in Operation and Maintenance (if any) in INR. On the benefit or savings side: Savings in Sodium Sulphide2 (17%)3 = INR …; Saving in water = INR …; Saving in process time = INR…; Sludge disposal costs at primary effluent treatment plant and common effluent treatment plant (PETP resp. CETP) = INR…; Electricity consumption at PETP / CETP (reduction in sulphide oxidation, lower BOD and COD load) = INR…; For ease of presentation an average payback period can thus be calculated. Please consider remarks in Footnote 1.

1 It may be considered if the subsidy – most of the technologies seem to be eligible for a Government subsidy of about 50% needs to be included as well. On the other hand, the cost of capital – interest rate – may need to be added. Then again equipment may be depreciated relatively fast giving another benefit. 2 Sodium sulphide is currently sold at INR 58 /kg. 3 Different way of presenting savings (17%, instead of 0.5% less offer)

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For the other PDUs, it is recommended that for PDU2 water management at small tanneries, shop floor training needs to be conducted first before the chemical savings can be quantified. Post this cost benefit analysis (CBA) in INR terms can be made. For PDU 5 chilled hides next to the already completed costing of electricity versus salt, one may consider to include investment in chilling facilities. Though this may make chilling much more expensive, it is expected that a full cost benefit analysis taking the cost of effluent treatment into account chilling may be not only the environmentally sounder options, but also the cheaper option. The dialogue with the nearby organised slaughterhouses maybe formalised in a Memorandum of Understanding with the aim to increase the use of fresh and / or chilled hides in the Kanpur region. For many of the smaller tanneries or those processing raw material (other than buffalo hides) PDU 6 – desalting will remain relevant. In the cost benefit analysis, there will be a cost benefit in soaking and thus in the effluent treatment cost. On process time the increase in time and human resources (desalting either with a vessel or a brush) needs to be offset against the reduction in process time (soaking). Ad 2) Steps have been taken to take the innovation award national and to make a distinction for different categories (See Annex 3 for full details). Ad 3) For water management at smaller tanneries (PDU 2): Installation of more water meters at selected small tanners as there seems to be some internal disagreement within STA members on who should (have) received these Ad 4) It was pointed out by the owner of Tej Industries that water meters per se and instructions to key technical staff do not lead to lower chemical usage. As chemicals are added based on float basis, this was expected, yet he did not observe it. The reason was given was that the workers were not properly educated nor trained. Post discussion with the team it is recommended that this can be tackled through the introduction of shop floor training (see further below for a possible outline). The basic outline of the shop floor training is as follows:

• 5 days over a period of two months • Each session has half a day theory and half a day practice • Session 1: Safety at the work place, chemical storage and handling, • Session 2: Good housekeeping, electrical and machine safety • Session 3: Environmental management • Session 4: Quality assurance, proper storing of raw, semi processed and fully

processed material • Session 5: Proper handling of machines and feeding of material in machines

It is recommended that UNIDO to prepare basic course material and field test it with partners in Kanpur, post which it can be modified and rolled out nationally

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Ad 5) Present data in different formats, for instance for the Government one may need to present the expected leverage on the Government investment of US$ 1 Million by the Industry. This is tabled below.

Updated on 2 April 2017

S. No.

Description Contributing organization

Contribution in kind, INR

Equivalent

Direct contribution

towards UNIDO

activities INR

Investment by tanneries on replication

(ongoing and within 1 year)

1 Office space, UPLIA 240,000

2 Office space KLC 240,000

3 Office support UPLIA & KLC 750,000

4 Workshops, seminars and meeting expenses

UPLIA, KLC, STA, industry 570,000

5 PDU 1: Hair save unhairing Kings Int. 465,000 6,000,000

6 PDU 2: Water mixing and measurement

Leayan Global 730,000 10,000,000

PDU2A: Water meters installations

20 meters in 4 tanneries 30,000 240,000

7 PDU3: Solar water heating system

Super Tannery 1,329,500 2,000,000

8 PDU4: Solar air heating system Calico Impex 2,767,000 2,500,000

9

PDU5: Processing chilled hides (raw material for trials) 350 hides, 2000 hide AKI Tannery 700,000 105,000,000

10 PDU6: Desalting Kings Int. 1,500,000 3,000,000

11 PDU7: Lime liquor recycling Kings Int. 1,500,000 1,500,000

12 PDU8: Water control in fleshing machines AKI Tannery 18,000 18,000

Grand total (column 4 and 5), INR 10,839,500 130,258,000

Grand total, US$ (1 US$= Rs.60) 180,658 2,170,967

Industry counterpart funding including chilled hides for one year is US$ 2.5 million plus (mainly from processing chilled hides, an installed capacity exist with organised slaughterhouses in the vicinity of Kanpur exist of 10,000 hides /d). From the table above the impact of chilled hides is clear. Yet impact can be much more significant once the technology package and the cost benefit analysis are out, for instance in the case of hairsave unhairing below are projections on investment and environmental benefits.

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The corresponding environmental benefits have been projected below. In the Kanpur Leather Development Project the industry has invested more than is shown in the Table above. Some investments that have been documented are below:

Energy savings in Ruksh International - replacement of two gear boxes for two drums at INR 500,000

Energy savings in Kings International tannery - energy audit, lighting improvements at INR 500,000

Energy audit by Model Tanners at INR 250,000

Investment for housekeeping improvements in Super Tannery at INR 500,000 For industry presentation cost benefit analysis and the expected environmental impact may be presented. Additionally, short videos may be prepared, particularly for PDU 5. Ad 6) For sludge reduction refocus on hairsaving Sludge production and generation can be reduced through ETP investment or through hairsaving technology (PDU 1). The ETP investment may take time in view of the developing scenario (refer Chapter 2).

Therefore, the Kanpur Leather Development Project rightly focused on hairsaving technology. Data has been collected and extrapolated on this (see above). Interestingly the tannery has identified a use for the nitrogen present in the hair (Photo left: Nursery at Kings International with gardener, aquaponics is another use).

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Finally it would be of great interest if the coordinator could seek an appointment with Mr. Jai Prakash, the person who has taken over the agri-fertiliser plant in Kanpur from ICI. As hair is a slow release nitrogen source and there is pressure on the chemical fertiliser industry in India to increase the percentage of organic inputs into their total production mix. Ad 7) Modify solid waste data collection to gather data on who collects it and at what price and where does it go to, baseline to contain flow charts Presently data collection is on solid waste generation from the tanneries, there seem to be little attention for current collection, conversion and disposal practices. Solid waste collection from tanneries is pretty-well regulated. To collect the sludge from the primary effluent treatment plants one needs a license. Furthermore, in the Unnao / Banthar cluster a special purpose vehicle has been set up for hazardous waste disposal. The site has two cells, both are in use, but have plenty of spare capacity. The leachate is pumped back to the CETP. The site has a a weigh bridge with record keeping and billing is done from the small laboratory. Visually only sludge could be seen. A similar set up is reportedly existing for the Jajmau tanneries, with the site being operated by a private party (Ramkey). For tannery solid waste, collectors sometimes charge for this (wet blue shavings and trimmings) and sometimes not (e.g. salt, fleshing in some cases). Not all of the waste is converted in new products in a safe manner (from both and environmental point of view). What is also missing in the current set up is the data collection from selected and proper solid waste conversion units (leather board, dog chews, glue, etc.) and the identification of their needs. Recommend to present the solid waste generation as a flow diagramme from generation to collection to conversion and disposal. Interestingly enough one can observe (maybe the time of the year) hardly any dumped solid waste from the tanneries.

At the same time an understanding has been reached with Prachi Leathers on a composting trial (PDU) for the hair. Organic waste (garden and kitchen) fleshing and hair (Photo left) will be combined either in the composting machine (Photo below) or through simple windrow composting and final product will be tested as per national compost guidelines.

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Ad 8) Conduct market survey tallow post technical feasibility and basic financial-economic feasibility It is recommended to expedite the technical feasibility study of tallow recovery by Flotweg, Germany. From this basic information can be obtained for a basic financial-economic feasibility (including possible use of subsidy for investment). For instance, a minimum price of the product will be derived at. One also needs to consider who would be the most suitable organization to possibly implement sucha technology, the Allaha Group (slaughterhouses, a tannery group, an existing organized glue unit?). If still required one could consider a market study, see also below. Ad 9) Assist regular solid waste conversion units in proposal preparation for Government to increase conversion. For instance, from the visit to a leather board unit (Bengal Leather Works (Banthar)). The unit uses 3 t/d of chrome shavings and 3 t/d of vegetable tanned cuttings shavings. They require substantial investment to upgrade their quality to get new customer segments and expand their capacity and thus also their demand for chrome shavings. Another leather board unit uses even a higher percentage of chrome shavings in their input mix. The Kanpur Leather Development Project could assist in preparing DPRs that the unit(s) can submit to the Government. Though we tried several times we were not able to discuss with the owner of a seemingly somewhat more organised glue making unit. It is recommended that this discussion is nevertheless held and that the Kanpur Leather Development Project could assist in preparing a DPRs that the unit(s) can submit to the Government.

Another conversion technology that place at some scale is the manufacturing of dog chews. This is normally done from raw trimmings (photo above), though for some varieties some amount of fleshings (photo right) can be used too.

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Ad 10) PDUs for solid waste conversion – composting / tallow

Ad 11) OSH start collecting accident data For OSH the demonstration at smaller tanneries need to start at the earliest. Secondly it is recommended that the Kanpur Leather Development Project starts keeping track of accidents both at CETPs and also in the cleaning of conveyance lines as well as at tanneries through the CETPs and trade organisations.

4.3. Adjusted workplan

As per the adjusted workplan, Output 1.2 will be finished earlier than originally planned. The baseline data collection (Output 2.1) will on the other hand be extended as more information needs to be collected from the (reuse) industries. Most other activities on learning and PDUs will continue as scheduled.

Year 1 Year 2

1 QT 2QT 3QT 4QT 1 QT 2QT 3QT 4QT

Output 1

Output 1.1

Output 1.2

Output 1.3

Output 1.4

Output 1.5

Output 1.6

Output 1.7

Output 1.8

Output 1.9

Output 2

Output 2.1

Output 2.2

Output 2.3

Output 2.4

Output 2.5

Fleshings can be composted. This has been proven repeatedly in tanneries in South India, vide UNIDO’ s technical report on composting). At Prachi Leather the same will be attempted for North Indian conditions and as demonstration. At the same time AKI has purchased equipment that will allow for tallow recovery (Photo left). The Kanpur Leather Development Project will assist AKI in the monitoring and data collection through yet another PDU provided the installation is completed well within the project period.

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5. CONCLUSIONS & WIDER RECOMMENDATIONS

1) In the months of March and April 2017 the Kanpur Leather Development Project was evaluated. As it was a mid-term evaluation both timeliness of activities and deliverables were assessed, but also the quality of the deliverable, the impact and, wherever feasible, its replication.

2) The evaluation was based on an assessment of the literature (to large extent the significant amount of technical reports prepared by the national and international experts), coupled with site visits, interviews, discussion with stakeholders, national experts, the project manager, review of relevant other documents (technical reports often available at LeatherPanel.org), photos coupled with personal observations and comparison with the situation at an earlier stage (1996). Based on all of this, I have attempted to make a comprehensive and objective evaluation. The responsibility for any errors lies with the author.

3) During the visit, several articles appeared in national dailies on the tanneries in Kanpur. The environmental situation in Kanpur has come under increased public and Government scrutiny. At the same time, several actions were taken or events happened that are directly relevant for the tanneries in and around Kanpur. The National Mission for a Clean Ganga (NMCG) has been converted into an implementation authority with full implementation powers. It is set up along the lines of a Ministry (central, state, district) etc. and has several committees working for it. Post the State elections in Uttar Pradesh, it now has the same Government at the Centre and in the State. Apparently, a contract has been given to CLRI to identify proper environmental solutions for the tanneries, particularly concerning waste water treatment. The zero liquid discharge is specifically mentioned as an option. Despite this, domestic investment in tanneries is high, more so in the Unnao and Banthar areas.

4) The Kanpur Leather Development Project is very well on track to meet all its objective, outputs and deliverables. In fact, it is most likely that deliverables will exceed against targets set at the beginning of the project by a substantial margin.

5) The installation of the core group is a strong point of the project for sharing and dissemination project related information.

6) The Kanpur Leather Development Project is in line with Government policies and objectives. The Project is also below the radar screen, which on the one hand safeguards it from any possible controversies, yet on the other hand hampers it in getting its results known to the outside world. Despite this, rreplication is already taking place without the technology packages being ready as data collection is still ongoing. It is expected that the industry will invest up to US$ 2.5 Million against the US$ 1 Million from the Government. Several actions were suggested to improve the likelihood of replication, its wider applicability or to improve the quality of the activity and corresponding deliverable. These were discussed with the project team and wherever deemed feasible adjustments were made in the workplans.

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7) Particularly for all sub-outputs and deliverables under Output 1 environmental management, project targets are exceeded. Sometimes the project targets are exceeded by more than 2 times (and this whilst the project is still ongoing).

8) Pilot and demonstration units (PDUs) are well appreciated by the industry. Most of the PDUs are on cleaner tanning processes and renewable energy. The PDU planned at Tej Industries (small tannery) for safety is going to have a very solid demonstration effect.

9) Applying good water management in tanneries reduces water consumption by 90,000 to 250,000 l per 10 t of raw material easing effluent treatment volume. Applying all cleaner technologies: chilled or fresh hide processing, hair saving unhairing, reliming liquor recycling, proper chrome management, using correct temperature in post tanning can bring overall TDS level in the effluent to 4,000 – 5,000 mg/l from current 15,000 – 20,000 mg/l. This makes effluent treatment much easier (and cheaper!!).

10) Occupational Safety and Health (OSH) measures were practically non-existent, especially in the smaller traditional tanneries. The project is rightly taken actions in this regard by demonstrating safety equipment, audits etc. At present in the small tanneries visited one cannot see protection bars at drums, presses with no safety working, an absence of protective clothing especially in beam house and chemical stores are not well organised. As far as lights are concerned the situation varies quite substantially. No records are being kept of work related illnesses and causalities, yet the project clearly aims to reduce this significantly, particularly through awareness raising and training on the highly toxic H2S gas coupled with distribution and explanation of handheld H2S meters.

11) Smart energy management can reduce the carbon footprint of tanneries significantly. Overall reduction in energy consumption in the tannery by application of solar energy (hot water / hot air) is around 15% (this includes energy from all sources (electricity, diesel, coal) and all processes including primary and secondary treatment of effluent). Savings of CO2 emissions are in the order of 100s of tonnes per year per factory.

12) Pre-audits for the Leather Working Group (LWG) were conducted and will continue. The LWG was formed in April 2005 to promote sustainable and appropriate environmental stewardship practices within the leather industry. The objective of the multi-stakeholder group is to develop and maintain a protocol that assesses the compliance and environmental performance of tanners and promotes sustainable and appropriate environmental business practices within the leather industry. This voluntary group represents a significant share of the global market! Without proper effluent treatment facilities meeting all standards in place tanneries cannot be certified by LWG auditors.

13) For Output 2, solid waste management, several tracks are being pursued. In the Jajmau area one notices immediately old disused machines, machine parts and other scrap, yet there is very little tannery solid waste lying around. The baseline data collection process focuses on generates, yet it is recommended to include collection and existing conversion and disposal as well. Strong point for all solid waste management activities is the existence of safe landfill site(s) with sufficient capacity. In

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time, some of the current solid waste conversion practices are unlikely to continue. Therefore, the Kanpur Leather Development Project correctly investigates some of the latest technologies in converting of tannery solid waste. Thus the deliverables should be finetuned / modified from project document to show more of a flow of solid waste from generation to conversion / disposal. In time, some of the current solid waste conversion practices are unlikely to continue.

14) In view of current uncertainty international joint ventures (JV) in solid waste management seem unlikely, yet in view of the strong domestic investment climate a technology transfer in solid waste management seems more likely than a JV. Therefore, the Kanpur Leather Development Project correctly investigates some of the latest technologies in converting of tannery solid waste.

15) The project has a strong focus on training with clear target groups, owners and technicians of tanneries. Being all adults they are voluntary learners. Adults learn best when the context of the training is relevant to their own lives and experiences. And when they are actively involved. Conventional training is not a very effective methodology for training adults as it ignores the integral role that adults play in their own learning process. UNIDO used a variety of training methodologies. These training methodologies had a high degree of practicals and were thus very well suited to the audience of adult learners. 733 people have been trained in on-the-job training, workshops, seminars, conference etc. This exceeds the target of 300 by far, whilst the project is still going on.

RECOMMENDATIONS FOR THE REMAINDER OF THE PROJECT - PUBLICITY

16) As the project is non-controversial and has results, it is recommended that a more active publicity will be sought in collaboration with KLC and CLE along the following lines.4

17) Inviting the Joint Secretary (DIPP) to witness the signing of a Memorandum of Understanding (MoU) between Allaha Group and AKI tannery on processing chilled hides.

18) Invite selected officials to visit few selected pilot demonstration units, in consultation with the local team, the solar air heating and hair saving, could be visited and flyers (one page handouts on these) could be distributed to the participants.

19) Invite through Council for Leather Exports (CLE), the Regional Chairmen and some leading tanners from that region to visit Kanpur and see some of the PDUs.

RECOMMENDATIONS FOR THE REMAINDER OF THE PROJECT - IMPLEMENTATION

20) Provide cost benefit analysis (CBA) of pilot demonstration units in Rupee (INR) terms.

4 This is completely in sync with the thinking of Mr. OP Pandey and Mr. Viswanathan. One could even say these are more their ideas, which I am writing down.

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21) Innovation Award as pilot to go national (CLE) and the Award for different categories – include study tour Tamilnadu

22) Install a few more water meters at members of the small tanners association

23) Pilot shop floor training for workers to maximize environmental impacts, e.g. of the use of water meters and other cleaner practices.

24) Present data collection in PDUs in different formats for different audiences; for industry in terms of INR (CBA); for Government replication, environmental impacts and industry investments (flyers). In case of chilled hides start preparing videos.

25) For sludge reduction refocus on hairsaving.

26) Modify solid waste data collection to gather data on who collects it and at what price and where does it go to, baseline to contain flow charts

27) Expedite market survey tallow post technical feasibility and basic financial-economic feasibility.

28) Assist regular solid waste conversion units in preparing DPRs for the Government to increase safe conversion of tannery solid waste into products.

29) Increase the number of PDUs! Particularly through introducing two new PDUs for solid waste conversion, i.e. composting of tannery solid waste and PDU on tallow manufacturing.

30) For occupational safety and health start the demonstration at small tanneries at the earliest and commence the collection of accident data.

WIDER RECOMMENDATION

31) To remain abreast of the best available technologies globally and the tremendous amount of goodwill created by the Kanpur Leather Development Project, it is recommended that the Government of India and UNIDO consider a successor project with roughly the following contours.

32) The focus should be on the circular economy with advanced improvements in the carbon and water footprints of the industry keeping in mind the different technology levels of industry, vide small and medium / large. Key interventions will be in safe reuse waste – possibly in combination with municipal waste - and reduction in the quantity and pollution load of waste water.

33) Activities to include best available technologies (globally) presented in the form of pilot demonstration units (PDUs) with full cost benefit analysis, technology packages and (inter)national disseminations strategies.

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34) Working with existing institutions (CLRI, KLC, etc.) to develop shop floor training & other training modules applicable for the entire country.

35) In close collaboration with CLE promote and facilitate exchange between clusters particularly in India, but also with those outside India, which have innovated in any of the relevant fields of cleaner production, safe reuse of waste or safety aspects.

36) Mainstream occupational safety and health for both small and medium/ large industry including waste water treatment systems (conveyance lines and wastewater treatment).

37) Support in institutional framework so that capacities developed will be anchored in appropriate institutions, be it laboratories, training institutions, KLC, CLRI, or trade organizations.

38) For smaller companies, the setting up of common facility centers with clear revenue models could be an option.

39) Development of capacity of Indian (private) companies to work in the fields of cleaner production, safe reuse of waste and renewable energy applications.

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Annex 1 JOB DESCRIPTION

UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

Job Description Project SAP ID: 100230

Project title: Kanpur Leather Development Project

(KLDP) Post Title: Leather Industry Expert

Main Duty Station and Location: Kanpur/India

Mission(s) to 14 days/Kanpur cluster

Start of Contract (EOD): 15 March 2017

End of Contract (COB): 20 April Number of Working Days: 21 working days (1 working month)

WAE

Background to the Project

Kanpur/Unnao leather development project will address sustainability and minimization of waste at source, cleaner tanning technologies in tanning sector, improving efficiency of effluent treatment plants, preparation a road map, bankable feasibility studies for common facility centers for leather production, common waste management facilities and productivity and quality improvement, which leads to improved performance of the companies and business linkages. At the same time, the ultimate objective of the proposed UNIDO Programme, taking into account the developmental responsibility within the framework of its mandate, is to improve employment possibilities for people in the regions where the targeted leather-clusters is located. Therefore, the Programme contributes actively to the enhancement of the performance of local SMEs to ensure their sustainable inclusion in domestic as well as international supply chains. As a result, the leather clusters will benefit from stronger backward linkages with a pool of local component suppliers, thus, increasing the overall impact of the Programme in terms of expanding and sustaining higher levels of employment, production, and exports, which will eventually contribute to income generation and sustained overall development. The overall objective of the Kanpur Leather Development Project (KLDP) is to enable local leather-based industry to sustain conversion of locally available raw hides and skins into exportable products, either directly as genuine leather or as derived finished product (e.g. footwear), thereby providing employment and income opportunities for the increasing population without jeopardizing the livelihood of the human settlements through environmental degradation threatening their rapidly depleting water sources and agricultural land. The following are the specific objectives of the project:

Environment sustainability & improved efficiency and best practices in leather processing

Waste Management

Details of Tasks The National Project Coordinator will work under the overall and direct administrative supervision of

the Project manager. S/he will be responsible for assisting the projectteam to implement some

activities, especially related to safety, and prepare mid-term evaluation report:

Summary of Key

Duties: Main duties

Expected duration

Location

Expected

results

1. Review and collect all files, documents and

background information

related to the project from PM and National

5 days Home based Documents and files collected

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Project Coordinator

(NPC)

2. Review project achievements, compare

with the work-plan and

project document, activities.

Preparation of

summary mid-term evaluation

5 days Kanpur/India Up-to-date status on the project

implementation

3. Assistance with

adjustment of the work-plan and activities

based on the findings

with special focus on safety for small

tanneries, Innovation

Award and solid waste.

Preparation of recommendations for

such actions if needed

ToRs etc.

5 days Kanpur/India Recommendations and

adjusted work-plan

4. Official inauguration

of PDUs

1 day Kanpur/India PDUs inaugurated

5. Presentation of findings and results of

evaluation to the

stakeholders

3 days Kanpur/India Project mid-evaluation

7. preparation of the

technical report

(midterm evaluation)

2 days Home based Technical report (Mid-

term evaluation)

MINIMUM REQUIREMENTS

BEHAVIOURAL COMPETENCIES

• Analytical thinking; planning, organizing and problem-solving abilities; good inter-personal skills

and team membership abilities; cultural sensitivity; excellent verbal and written communication skills; report writing skills; ability to work under pressure and to meet tight deadlines; willingness to

keep abreast of new developments in the relevant technical field.

QUALIFICATIONS AND EXPERIENCE

Advanced University degree, preferably in leather technology, chemical science or similar

Experience in leather industry at least 10 years Experience in training and education (particularly leather technology) will be considered a strong

advantage

At least 5 years of practical experience in project management, part of which preferably with a

UN organization Sound knowledge of project management activities and coordination; including project

monitoring and evaluation

Possesses good communication and interpersonal skills, and has demonstrated the capacity to deal effectively with sensitive issues

Proven ability to work as a member of a team with good inter-personal communication skills Expert should complete UNIDO on-line training course “How to deal with hydrogen sulphide gas”

LANGUAGE AND COMPUTER

Fluent in written and spoken English,

Computer literacy and strong working knowledge of Microsoft Office, and knowledge of spreadsheets and databases are an asset

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Annex 2: VISIT PROGRAMME

26 March, Sunday 20:45 Arrival of Kanpur 27 March, Monday UNIDO KLDP Office, UPLIA, KLC Complex, Banthar

Introduction of project team & programme finalization Project objectives, outputs Kanpur leather industry Achievements in the project – Progress so far Training activities Facilities in KLC Review of earlier done and planned activities

28 March, Tuesday Visit to Super Tannery, Jajmau

Solar water heating system Onsite training on cleaner technologies, (Mr. Patrick Zerhusen)

Energy and carbon footprint assessment (Ms. Jutta Knoedler) eLearning on LMT, H2S courses Visit to Leayan Global

Water mixing cum measurement system Onsite training on cleaner technologies, (Mr. Patrick Zerhusen), OSH

Energy and carbon footprint assessment (Ms. Jutta Knoedler) eLearning on LMT, H2S courses

29 March, Wednesday Visit to Kings International tannery

PDUs on Hair save unhairing, Desalting, Lime liquor recycling Onsite training on cleaner technologies, (Mr. Patrick Zerhusen) Energy and carbon footprint assessment (Ms. Jutta Knoedler) eLearning on LMT, H2S courses

Visit to Calico Impex Onsite training on cleaner technologies, (Mr. Patrick Zerhusen) Solar air heating system

30 March, Thursday Visit to Makhdoom Tanning Industries

Meeting with Small Tanners Association Water metering

Visit to Kings International tannery Meeting Chairman

31 March, Friday Visit to Unnao CETP Visit to Banthar CETP Visit to Banthar Hazardous waste management disposal site 1 April, Saturday Free day

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2 April, Sunday Free day 3 April, Monday Visit to Makhdoom Tanning Industries

Joint visit and collecting members of NMCG Visit to Jajmau CETP and wastewater discharge line Discussion with a solid waste conversion unit owner Discussion with Mr. Shamsuddin (leather “meal”) Visit to Tej Industries

Water metering H2S safety demonstrations OSH pilot demonstration unit (ongoing)

4 April, Tuesday Meeting CLE Chairman Visit to Ruksh International, Banthar

Energy and carbon footprint assessment (Ms. Jutta Knoedler) On-site training on OSH, H2S safety eLearning on LMT, H2S courses

STA Hafizul Rahman (President) – more names to come 5 April, Wednesday Bengal Leather Works (leather board) Tallow man (second effort) Visit to AKI Tannery

Chilled hides processing Water control in drums and fleshing machine Onsite training on cleaner technologies, (Mr. Patrick Zerhusen) Energy and carbon footprint assessment (Ms. Jutta Knoedler) eLearning on LMT, H2S courses

6 April, Thursday 11:00 – 13:00 Visit to Prachi Leathers

ETP improvement Onsite training on cleaner technologies, (Mr. Patrick Zerhusen) eLearning on LMT, H2S courses

14:30 – 15:30 Visit to Jama Corporation eLearning on LMT, H2S courses

7 April, Friday 10:00 – 16:00 KLC Planning tomorrow’s meeting and phase II concept note 8 April, Saturday Meeting with UPLIA members Review progress Recommendations for change Planning for phase II concept note Wrap up meeting Departure from Kanpur

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ANNEX 3: PILOT INNOVATION AWARD

WHAT IS THE INNOVATION AWARD

The objective of the INNOVATION AWARD (INNA) is to award industries to improve innovation in the environmental field, be it the working environment (occupational safety and health), environmental impact of the industry in terms of water reduction, carbon saving or waste reduction.

It is a pilot as the Kanpur Unnao Leather Clusters Company Ltd (KLC) is launching this in close collaboration with Council for Leather Exports and UNIDO Kanpur Leather Development Project (KLDP). This project is promoting cleaner tanning technologies, best practices in occupational health and safety and better solid waste management practices to achieve improved environmental footprint. The tanning industry in Kanpur is diverse. There are very modern factories with a strong focus on exports of leather, shoes, goods, etc. There are traditional companies who primarily produce for the local market using vintage machines. Innovations at their level will be different in scale, vision, but not necessarily in impact. In recognition of ground realities, there will be 2 Awards. One is for “small” tanneries defined as producing from raw to semi-finished. The other award is for “larger” factories from raw to finished leather. UNIDO will draft criteria and in close collaboration with the KLC and Council for Leather Exports these will be field tested. Field testing include appropriate criteria for distinguishing between large and small tanneries. Post field testing and necessary adjustments, the Council for Leather Exports will take it up at National Scale.

BACKGROUND INFORMATION

Several tanneries have innovated production practices and processes. These practices could benefit others and assist in improving the overall image of the industry, the award will be a way of recognising their innovation at national level. The overall objective is to enable the Indian leather industry to sustain conversion of locally available raw hides and skins into exportable products, either directly as genuine leather or as derived finished product (e.g. footwear), thereby providing employment and income opportunities for the increasing population without jeopardizing the livelihood of the human settlements through environmental degradation threatening their rapidly depleting water sources and agricultural land.

WHO CAN PARTICIPATE?

In the pilot phase, participation is limited to tanneries from the Kanpur region only. Participants may be tannery owners, managers, technicians – leather, electrical, mechanical, civil, chemistry, shop floor staff, sales staff etc. Individuals may participate, but they may also form a team. SUBMISSION FORMAT

The participants may submit their entries using:

Photos from a smart phone with an audio recording

Video recording

PILOT INNOVATION AWARD

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Written report with photos Submission may be in English or vernacular (Hindi) SUBMISSION DETAILS Each participant is expected to

1. Describe the situation prior to the innovation 2. Describe how your innovation improves the situation in the tannery in terms of water saving,

energy saving, chemical saving, working conditions improvement or solid waste improvement 3. Estimate benefits above in quantity of water saved, energy saved, chemicals saved, lower

accident rate or solid waste reduction, reuse of recycling 4. Only if possible give the above in terms of Indian Rupees 5. Request the factory owner or technician to give his views on your innovation (endorsement).

This may be in writing, audio or visual 6. Send your submission to the Convenor.

CALANDER

Launch of innovation award 3rd March, 2017

Registration begins by 3rd March, 2017

Last date for submission 30th June, 2017

Announcement of Results 15th July, 2017

EVALUATION CRITERIA

For the two categories, small and large the judges will evaluate submissions on the basis of the following criteria:

1. The situation before the innovation 2. The innovation in terms of completely new or seen somewhere and adjusted 3. The impact of the innovation in the tannery in terms of increased workers safety, water

saved, energy saved or waste saved. 4. The scope for replication the innovation in other industries of the same size group

For each the Jury will award points and the highest scorer will be the winner.

JURY MEMBERS

The following eminent industry representatives and experts will constitute the jury: 1. Mr. R.K. Jalan, Chairman Sustainability Cell, Council for Leather Exports 2. Mr. O.P. Pandey, Executive Director, Kanpur Unnao Leather Clusters Company Ltd.

(convenor) 3. Mr. Ivan Král, Industrial Development Officer, United Nations Industrial Development

organisation, Vienna 4. Regional Chairman, Council for Leather Exports, Kanpur 5. Representative of Central Leather Research Institute

WHAT WILL THE WINNER GAIN?

The selected winners and the tanneries will get the Innovation Award Jointly from KLC, UNIDO and Council for Leather Exports, one for each category. This will be widely publicised. As a special promotional effort the winner from each category will be entitled to participate in the Study Tour organized by UNIDO KLDP project to gain additional experience on Sustainable Cleaner Production in tanning industry. Runner ups in each category will be taken on a study tour of South India tanneries organised in collaboration with the council for Leather Exports.

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Authors of the best proposals may be included into UNIDO expert’s roster. The KLC, Council for Leather Export and UNIDO KLDP project reserves right not to nominate any participants in case that the submissions are not up to standard expected for the innovation award.

FURTHER INFORMATION

For further information please contact: Mr. O. P. Pandey Convenor: Executive Director Kanpur Unnao Leather Cluster Development Co. Ltd. KLC Complex, Kanpur – Lucknow Highway Village Kader Patari, Unnao – 209 862 Uttar Pradesh, India Tel: 0515-282 3182 Mob: 09918915682 E-mail: op1955@rediffmail.com

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Annex 4 DETAILS OF VISITS

Discussion at Super tannery with buyers (Lambs) on meeting the requirements of the Leather Working Group. The tannery is working on several improvements and UNIDO’s presence was well appreciated. As Lambs pointed out, the buyers want to play safe are afraid of reputational risk. For UK and perhaps European buyers a LWG certificate is a way to minimise risks. Both Lambs and UNIDO pointed out that without proper effluent treatment the tannery would not be able to obtain this certificate. Production of leather in and around Kanpur remains a mystery. For instance, it is commonly estimated that in Jajmau about 30 larger tanneries exist each producing 20 t/d, some medium sized doing 5 – 10 t/d and smaller ones doing between 0.5 – 2 t/d. The same applies to Banthar / Unnao, though quantity of effluent to the CETPs is regulated the concentration of TSS in the waste water indicates that the production may be (much) higher than indicated. On a positive note this implies that most tanneries have optimized their water usage. Chilled and even fresh hides are slowly being recognised as a real alternative. Earlier KINGs International had been processing imported chilled hides. Why tanners start seeing this – despite several challenges as they also quickly point out – within a radius of 300 km of Kanpur 40% of slaughter takes place. PDU 6 when doing the cost benefit analysis, the salt that is collected is taken for free by raw hide dealers; though there is additional expenditure in the form of equipment, labour for loading the raw material and collecting the salt, there are savings in terms of water (1 soak instead of 2), corresponding electricity and time savings. The main saving – which cannot rally be calculated today is in the form of savings on effluent treatment. In Super tannery removal of salt by brush will be studied. PDU 7, reliming liquor recycling, cost benefit analysis. In few tanneries in South India settled lime was mixed with other materials and used in flooring On H2S, reported casualties in Kanpur are 4 / 5 per annum but this could not be substantiated with actual data. In 2014 there was an accident in the conveyance lines. Insurance information is obtained by phone from Rajesh George (management system facilitator, amongst others ISO 14000, ISO 9002). Discussion can OSH be promoted through reduction in insurance risk premium? Apparently in Indian conditions as per the Factory Act (with 10 more employees) insurance cover is compulsory. Employees compulsory covered Indian Standard Insurance (ISI), as per 1 January 2017, the salary limit is INR 21,000 and employers’ contribution is 4.75%. Employees contribution – deducted from salary remains at 1.75%. Treatment at Government hospital and some private hospitals covered including partial salary payment. However, unlike Europe there is no distinction in premium payments if the factory has a lot of accidents (higher premiums) or few or no risks (lower premiums, no claim reductions).

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Lime splitting is not happening in Kanpur. The reason is that there is very little demand for lime splits. On the other hand, for wet blue splits one can get paid in advance. For finished leather, typically it goes on a 1 month credit. Feedback by the industry on waterless chrome tanning – developed by CLRI - was moderately positive. CLRI is selling it as technology to the industry at INR 250,000. Converting fleshings into biogas – Rehau energy is ongoing. A revival of the Melvisharam plant is not possible. As they are not under contract it is difficult to say when the result will come in. The nearest cement kiln is about 300 kilometres away. Though they may accept most solid waste for use in their kilns, conversion of trivalent chromium could be an issue. Solidaridad, supported small tanners by giving to off them a 50% grant to purchase on line flow metering costing INR 23,000. Field visits (some additional observations that have not been used in the main report): Discussion at Tej Industries (member of STA), 2 or 3 tanneries are his friend. Between them they share capacities (machines and drumming). The same applies for Muhkdom. Bengal Leather Works (Banthar) Leather Board (Abu Khan, 2 brothers with the same name) Capacity 500 boards per day (size about 1.4 m2); input 50% Chrome shavings (3 t/d purchased from transporters at INR 5/kg) and 50% vegetable tanned cuttings (equestrian) at INR 6 /kg. Adding latex and Alum; thickness varying from 0.6 mm to 5 mm. Product innovation (see pictures). Photo above: placemat Photo right: umbrella stand New machine replacing Hollander Beaters (2) can improve the quality of the boards further. Investment costs is about INR 20 – 30 Million. Old roller coater (upstairs), use of solar and OSH, the basic design steps combined with practical experiences from operation of reed beds for tannery effluent quite often resulting in modifications in its design and lay-out, the current design has been derived at. The Jajmau CETP

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Discussion with the in-charge. During some periods (Mellah in Allahabad) tanneries need to stop or reduce their production. This was given as an explanation for the low TDS in the wastewater. At the same time TDS in domestic waste water is quite high indicating that tanneries and other industries discharge in domestic wastewater systems. Unnoa and Banthar CETPs, the common part of the CETP still needs to be better understood by the members. For instance, the TSS that is send to the CETP is much higher (4,000 – 10,000 mg/l) than agreed (600 mg/l) and hence the sludge treatment costs at the CETP is higher meaning the CETP and ultimately it is the members that need to pay more. This is confirmed by the records of the SPV – hazardous waste landfill site.

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Some other points which are equally difficult to categorise: At Unnoa CETP a piece of equipment could be seen that has been installed by Mauris Environmental Company (Schijndel, Netherlands). With a grant from the Royal Netherlands Embassy of reportedly € 400,000 the idea was to convert fleshing into oil and energy. Again as per the reported information that instead of the projected 40 t only 1 t of fleshing was the input. Furthermore, using 500 l of diesel and 1 t of fleshing the output was 240 l of crude. Based on this info - a Dutch investor (Erik de Boer) that came to visit decided not to invest. Prachi Leather, ETP upgradation. If design comes could be considered to get a second opinion from Mladen Bosnic (nitrification – denitrification) Together with Stahl exposure has been expanded to include Ambur (300)

In theory primary sludge from the tanneries’ primary effluent treatment plants should be much higher than sludge form the CETPs. Records show this is not the case. The SPV receives more than half of its sludge from the Banthar CETP, i.e. 235,500 tonne of sludge against a total received of 426,765 tonne of total sludge received. (see photo left: records kept at SPV – Hazardous Waste Landfill site (needed for billing)) More than a technical issue, the root cause seems to be an organisational issue to be taken up at Director’s level. If not done it becomes a technical issue as the CETP is not designed for these pollution loads.

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Participants feedback to common sense is that there are issues with registration.

Main points of discussion with Tatheer Zaidi (Solidaridad, New Delhi 8 April 2017),

Just a few of the action points: programme in Kanpur to 2020. Collaboration opportunities with existing UNIDO project (end 2017, though successor project is one of my recommendations) are in: 1) Scaling pilot demonstration units 2) Trainings (already somewhat ongoing) 3) Support in strengthening tanners associations 4) Solid waste conversion 5) Coordinated approach to Government and other stakeholders

Sustainable Water Fund project met all criteria and is now going for content review.

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Annex 5: PEOPLE MET

Name Organisation Other info

Mr. Abu Khan Bengal Leather Works (owner) Leather Board manufacturing + raw – wet blue tannery, Banthar

Mr. AK Rai Prachi Leather (head business unit) Raw to finish, ETP advice & possible compost PDU

Mr. Imran Siddiqui Super Tannery (director) PDU 3 solar water heating

Mr. Aamir Awsaf Kings International (management rep)

PDU2; OSH; PDU 6; PDU1 etc.

Mr. Andy Cook William Lamb (design director) Questions about LWG certification Super tannery

Mr. Aditya Kumar Singh Solidaridad (Senior associate) Having project in Kanpur, submitted proposal through FDW

Mr. Farhan Ajmal Calico Trends (partner) PDU 4

Mr. OP Pandey KULCD Co. Ltd (ED) Director counterpart and strong support publicity

Mr. Kanojia Jajmau CETP (chemist) Acting CETP in charge

Mr. TN Mehrotra Jama Coop (in charge) Very interested to innovate, suggested to use solar cooling used in environmental architecture

Mr. V. Lakhtekia Jama Coop (GM tannery section)

Mr. Mobi Amin Super Tannery (CEO)

Mr. Samir Kumar UNIDO (NE Training)

Mr. M. Viswanathan UNIDO (NPC)

Mr. Naiyer Jamal Makhdoom Tanning Industries (partner)

Mr. Asad Iraqi AKI (Managing Director) PDU 6, PDU 2, PDU 5, PDU tallow

Mr. S. Suthanthararajan CLRI (Head Environment Dept)

Mr. Tej Alam Kings Intern (Managing Director)

Mr. Mukhtaral Amin Super House, Chairman CLE

Mr. AK Singh Kushwaha Leayan (GM Production) Mr. Chauhan Leayan (ETP in charge) Mr. Bikram Chakraborty Leayan (marketing) Mr. Raj Kumar Leayan (dye house in charge) Mr. Farhan UNIDO Mr. Carlos Alberto de Oliveira Silva William Lamb (sr manager India

office)

Mr. Arjun Yadhav UNIDO (leather technologist) Others are at the attendance sheet

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Annex 6: STAKEHOLDERS MEET

Minutes of meeting on interactive session with Mr. Valentin Post, International Expert on mid-term evaluation of UNIDO Kanpur Development Project on 8/4/2017

United Nations Industrial Development Organization (UNIDO) has been implementing a Kanpur Leather Development Project since November 2015. The objective of the project is to demonstrate the cleaner tanning technologies, occupational safety and health related aspects in tanneries and feasibility studies for solid waste management. A mid-term evaluation on the progress of the implementation of the project and impact created by the project was instituted by UNIDO. Mr. Valentin Post, International Expert conducted the evaluation from 26 March 2017 to 8 April 2017 by visiting several tanneries, CETPs, solid waste conversion units and interacting with them. At the culmination of 2-week long evaluation, an interactive meeting with industry representatives was organized by Uttar Pradesh Leather Industries Association (UPLIA) and Kanpur Unnao Leather Cluster Development Company (KLC) on 8 February 2017 in KLC Complex, Banthar. A list of participants of the meeting is provided in Annex 1. Mr. O.P. Pandey, Executive Director, KLC welcomed the participants and he mentioned that the project has demonstrated several positive examples and it is the time now to propagate the results among the industry widely so that the industry will adopt those positive practices. Further he mentioned that with the support of CLE, a workshop will be organized inviting industry and top officials from the Government of India and Government of Uttar Pradesh to showcase the achievements of the industry in Kanpur region. The Innovation Award (INNA) has also been instituted with the support of UNIDO to encourage the tanneries to adopt best practices in cleaner technologies, energy conservation, water conservation and occupational safety and health related aspects. A study tour to Germany will also be organized by UNIDO in which a representative from each of the stakeholder organization will participate in the study tour. Mr. M. Viswanathan, National Project Coordinator, UNIDO KLDP introduced Mr. Valentin Post. He mentioned that Mr. Valentin Post has been associated with leather industry and UNIDO since 1993. His area of experience is waste management and his countries of expertise are many South East Asian countries such as India, Bangladesh, Nepal, Philippines, Sri Lanka and Indonesia and a number of African countries.

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Mr. Valentin Post, International Expert made a presentation of the findings on the evaluation of the project, highlighting the status in visual form. The following are the main points:

Training courses and training programmes: The project has delivered 4 training

courses and two more are under development, though only one training programme

on sustainable leather manufacturing was proposed in the beginning. Though the

project envisaged 300 persons to be trained, until now the project has already trained

about 733 and still some more trainings are scheduled. This results exceeds the

expectation beforehand.

Innovation award: Though it is still ongoing, this will be completed before the end of

the project. Further he was optimistic that with the active collaboration of CLE and

based on the pilot testing in Kanpur, this awarding system is likely to go national level,

which will exceed the expectation.

PDUs: In total, there were 8 technologies demonstrated though only 3 was proposed

in the beginning and many of these technologies are the first-of-its-kind in India. The

technologies follow the principle of reduce, reuse and recycle concept. The

technologies demonstrated resulted in reducing the pollution load in the tannery

effluents in terms of pollutant parameters such as BOD, COD, TDS and TSS.

Technologies to reduce the solid wastes like hair save unhairing, water conservation

by measurement, improved uptake of chemicals that reduces the wastage of

chemicals and solar assisted water heating and air heating systems were also

demonstrated. He mentioned that he is happy to note that the tanneries have started

to replicate these technologies based on the encouraging preliminary results even

while they are still under close monitoring. The UNIDO team will further monitor the

PDUs and bring out cost benefit analysis in Rupee terms for easier understanding of

the financial implications (cost benefit analysis). This result exceeds the expectations.

Best practices and sustainable production- pilot audits: Energy & carbon footprint

assessment, comprehensive energy audits and use if benchmarking to adopt best

practices were completed, which satisfies the expectations. Implementation of audit

findings are also ongoing which is expected to result in more positive results.

OSH: Deliverables such as assessment in tanneries completed in two tanneries, OSH

PDU on H2S gas meters completed, demonstrations in the shop floor conducted,

manual translated into Hindi. PDUs on OSH in smaller tanneries, machine, electrical

and chemical safety are planned, but yet to start.

Screening of technologies for sludge reduction: Evaluation of ZLD & non ZLD

completed andpresented at IULTCS; sludge reduction is ongoing which should

(re)focus on hair save unhairing.

Waste management: Strong point for tanners is existence of SPV and secure landfills.

Data collection from tanneries on solid waste generation and preparing a baseline

report is ongoing. The report should include data on selected and proper solid waste

conversion units (leather board, dog chews, glue, etc.) and their needs should be

identified. During the visits some unacceptable methods of solid wastes conversion

are also noticed. He mentioned that will be discontinued at one point in time, either

by increased awareness of the authorities or the public. Though delayed, this will be

completed before end of the project.

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Feasibility reports: A report on solid waste utilization is already prepared and issued.

Feasibility reports for tallow and biogas production are ongoing. Based on the

feasibility reports bankable project reports can be worked out, if so required with a

specific market scan to boost its robustness. Improved tannery design as a template in

process. Overall comprehensive plan is expected to be presented to tanners by end of

October 2017.

Conclusion: Project is well on track to meet its objective and outputs. Installation of

Core Group is a strong point. PDUs are well appreciated by the industry. Replication is

already taking place without technology package being ready as data collection is still

ongoing. Particularly for all sub-outputs and deliverables under Output 1

environmental management, project targets are exceeded. Sometimes project targets

are exceeded by more than 2 times (project is still ongoing). Output 2 is somewhat

delayed, but this delay should be made up in the last months of the project.

Recommendations for activities within the project: Innovation award winners should

also have a study tour to Tamil Nadu, where some very relavtn water saving practices

in tanneries and end-of-pipe treatment practices (ZLD) are taking place may be for the

runner-ups. Measurement of water should be further strengthened with few more

water meters at smaller tanners and shop floor training. Cost benefit analysis should

be done for all PDUs in Rupee terms. Promotion materials such as flyers, video films

should be developed on PDUs. Solid waste data collection should also have details on

existing practices. Market survey for tallow should be taken after the technical

feasibility. PDUs for solid waste conversion – composting / tallow (including recovered

hair) with the support of the industry to be taken up.

Recommendations beyond the project activities: UNIDO, Industry and the

Governments may consider a national successor project on the following contours:

circular economy, advanced improvements in carbon and water footprints, capacity

development in Indian companies, best available technologies globally presented in

the form of PDUs, shop floor training on cleaner technologies, occupational safety and

health aspects, exchange programmes with clusters within and outside India,

improvements in OSH and institutional support

While expressing Mr. Valentin Post that the overall project progress is satisfactory so far, he thanked the industry for support extended to the project and taking it forward. To a query of Mr. Iftikharul Amin, Hony General Secretary, UPLIA, Mr. Taj Alam mentioned that the duration for desalting of one tonne of material takes about one to two hours and the cage has got the tilting mechanism which can modify the travelling time of hides in the cage. Mr. Viswanathan mentioned that the hides travel about 4 to 6 minutes in the desalting cage before it falls on the other side the cage to the side which is fed. Mr. Farhan Ajmal mentioned that the it will be good to include the plants for solid wastes in the large scale zero liquid discharge plants funded by the NMCG in the three clusters. Mr. Viswanathan and Mr. Post mentioned that the feasibility studies being conducted by the two German companies for conversion of fleshing into value added products (tallow / bio gas) will be expedited and presented for consideration by the industry and Government. Mr. Post

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suggested to consider also to consider establishing plant()s converting the fleshings into an additive to poultry feed as is practiced in South India. During the discussion on possible reduction of TDS in effluent by adopting all cleaner technologies, Mr. Farhan mentioned that as about 40% of all slaughter in India takes place in a 300 km radius from Kanpur, the effluent charges should be based on the pollutant parameters like TDS content in the effluent which could bring an incentive for the tanneries to adopt cleaner technologies. He added that in case of such incentive, it may be become possible for many tanners to process either chilled or even fresh hides as some of the tanneries could find ways to access fresh hides to the extent of their possibility. Mr. Taj Alam mentioned that the market mechanism may lead to increased price of chilled or fresh hides, as the demand for fresh or chilled hides increase to avail the incentive in treatment cost. Mr. I Amin mentioned that water control in fleshing could save good amount of water as it will avoid flow to the machines whenever it is not required. Mr. Asad Iraqi mentioned that this control system is possible with a minimum investment of about Rs.18,000 per machine. Mr. Taj Alam, while concluding the meeting, thanked UNIDO and Government of India for selecting Kanpur region for this project and he mentioned that the project has come to Kanpur timely, when the industry is looking forward for cleaner technologies. He mentioned that demonstration events will be organized in the each of the pilot demonstration units and the industry representatives will be invited to see for themselves the technologies demonstrated by UNIDO. He suggested that Mr. Post would include in his report the strong desire of the Industry (echoed by those present) that UNIDO considers continuing its support to the industry beyond the current project. Prior to the start of the meeting, the following informal discussions were held: During a stakeholder meeting on 7 April 2017, which was organized by MoWR, GoI and NMCG and attended by CLRI, TWIC, CPCB, UPPCB, tanners representatives, it was decided that three zero liquid discharge systems will be installed in Jajmau, Banthar and Unnao CETPs respectively. NMCG will fund the establishment of these plants completely. It is estimated roughly that the cost of implementation will be about Rs. 850 crores for Jajmau with a capacity of 20 mld and Rs. 250 crores for Banthar and Unnao. Shifting of the tanners from River Ganga will not be pursued by Government of UP. CLRI presented the plan on how to reach the ZLD over a period of 6 years and it was noted that the CLRI will chose the technology so that the cost of operation of ZLD plants will be kept below 2% of the cost of finished leather. The plan includes implementation of cleaner tanning technologies in the first two to three years. It is also expected that a single contractor appointed by a single tender for all the three plants will implement the plants and expected to operate and maintain the plants for 10 years.

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Participants of interactive session with Mr. Valentin Post, International Expert, UNIDO on 8 April 2017

S. No. Name of the participant Organization 1. I. Amin UPLIA, Super Tannery Ltd

2. Taj Alam UPLIA, Kings international Ltd.

3. Ashraf Rizwan UPLIA, Homera Tannery

4. Farhan Ajmal UPLIA, Calico Tannery

5. Asad K. Iraqi JTA, AKI Tannery 6. Hafizur Rahman STA

7. Shahansha STA

8. Uzair Anwar UPLIA, Ruksh International

9. Rizwan Khan JTA 10. Amir Rizwan JTA

11. O.P. Pandey KLC

12. A.R. Khan Super house

13. Sultan Ahmad Zaz Tannery 14. Asif Iqbal JTA

15. Nurullah JTA

16. M. Haque Leder Fabric

17. Raja Suresh Yadav Raj Tannery STA 18. Valentin Post UNIDO

19. M. Viswanathan UNIDO

20. Samir Kumar UNIDO

21. Syed Md. Farhan UNIDO

22. Arjun Yadav UNIDO

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Annex 7: TRAINING

Adult learning – the theory5

Adults continue to learn throughout the years (Sterns & Doverspike, 1988); however, they may take longer to learn new things. Although young people seem to be more efficient when it comes to memorizing information, older people are better able to evaluate and apply information. That is easier for adults than for children, as their brains can do a better job of connecting new information with information they have already stored (Silberman, 2006), as they simply have more information stored already. If you would compare knowledge to a house, then the brains of an adult would be an experienced mason, who can easily adjust the design of the house to new insights, and decides to construct an extra unplanned floor in the house, or to use a new type of isolation material, or to improve the design while constructing, as he remembers the mistakes he has made 10 years ago. This experienced mason however, may have more difficulties in remembering the amounts of bricks he has ordered last week and the names of his new colleagues. Key points for training adults. Adults

need to be responsible and involved in planning, implementing, evaluating their learning,

base their learning on past experiences (more than children), expect training to be directly relevant and practical to them (in their jobs),want real-

world application, may be motivated more by internal factors

The key principles of adult learning are summarized below along with their implications for training in the form of a checklist’ (Table 1).

Table 1: Key principles of adult learning and facilitator’s checklist

Principles of Adult Learning Facilitator’s Checklist

Adults are voluntary learners and will perform best when they have decided to attend a training session for a particular reason.

Do you know why participants are attending? Has the selection of participants followed a process (checklist)

Adults learn best when the context of the training is relevant to their own lives and experiences.

Have participants been asked to share their expectations and what they hope to achieve by the end of the training program? Do you have a system for guiding participants whose expectations are not well matched to yours or the groups?

5 This session is obtained from the Learning Guide, WASTE 2015

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Adults have experience and can help each other learn through an atmosphere of sharing.

What prior knowledge may trainees have about the subject matter of training? Will your training methods build upon and use the ideas and skills of participants?

Adults learn best when they are actively involved.

Does the training include regular opportunities for feedback, reinforcement and practice?

Participatory and conventional training Participatory training methodologies differ significantly in terms of process and objectives from conventional training.

Table 2: Conventional and participatory training

Elements Conventional Training Participatory Training

Learner’s Role

Follow instructions. Passive participation. Receives information. Little responsibility for learning process.

Offer ideas based on experience. Active participation (ask questions, make mistakes as part of the training process). Share ideas and experiences. Take ownership of learning process.

Trainer’s Role

Is an authority figure. Ignores learner’s knowledge and experiences.

Is a facilitator. Respects participants’ knowledge and experiences.

Training Content

Trainer-controlled. Little choice provided on topics.

Learner-centred. Based on participants’ training needs.

Method Focus

One-way flow of facts/information from trainer to learner.

Two-way communication building on knowledge and experiences of participants and trainer.

Source: WSP 2007, Adapted from CEDPA (1995). Conventional training is not a very effective methodology for training adults as it ignores the integral role that adults play in their own learning process. Adult learning is based on principles and conditions that are different from the conventional set of learning principles. Humans have selective perception. Usually there is more stimulation in the environment around us than we are capable of attending to and storing in our memory. Therefore we only focus our attention on things that interest us because they are:

Related to what we already know, or So new or strange that they force us to pay attention to them.

Many researchers have tried to structure the human learning process. For instance, Kolb's learning theory sets out four distinct learning styles, based on a four-stage learning cycle: (1) Immediate or concrete experiences lead to (2) observations and reflections, which are then (3) assimilated (absorbed and translated) into abstract concepts with implications for action,

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which the (4) person can actively test and experiment with - and which in turn enable the creation of new experiences, completing the cycle (Table 7.3).

Table 3: Kolb’s Learning Stages

Kolb learning stages Concrete activities Examples

Concrete Experience (CE) Familiarize Get ideas, share experiences Order, prioritise

Reflective Observation (RO) Grasp, comprehend, analyse Explain, structure Form opinions, find answers

Abstract Conceptualisation (AC)

Reinforce

Active Experimentation (AE) Apply, synthesize Theoretical Social Technical

Two tendencies in training need to be mentioned:

1. Trainers prefer to use linguistic training methods, while research indicates (Lawson, 2006), that more adults are visual learners preferring any other perceptual style.

2. Trainers prefer to use theoretical training methods (often coinciding with linguistic intelligence), while many people learn by doing, or practical, (sometimes coinciding with the bodily-kinaesthetic intelligence). According to Lawson (2006), when participants do the work (instead of the trainer), they transfer new information into long-term memory, instead of their working memory.

A general advice can be given: By applying training methods focusing on different senses, not only participants with different preferred intelligences will be reached, but the learning of all participants will be reinforced by receiving information in other ways than just their own preferred perceptual style.

Teach or be taught? A fundamental question that has to be answered to decide between organizing (or participating in) a facilitated training programme and self-learning is why you want a training programme. For, there are differences benefits to both – and of course, different costs! There are two main reasons to teach yourself.

Efficient and specific (You yourself know and can answer to your own training needs the best)

Cheap (few costs, little loss of productive hours) Similarly, two main reasons to be taught or trained are:

Effective (can reach many people at once) Helps create a common understanding of a programme or project

Training methodology used

UNIDO prepared a staggered structure of training, so that a variety of training methodologies could be used. This outlined in the drawing below.

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(1) International experts (IE) on short mission worked on the job with national experts (NE)

(2) IE and NE worked in the various tanneries with the leather technologist, electrical or mechanical maintenance persons, or those in charge for OSH as well as management. These were direct practical training.

(3) IE, NE and the leather technologist, electrical or mechanical maintenance persons, or those in charge for OSH. Made trial runs quite often in cleaner production processes (hair saving etc.) but also in energy or OSH. The skills imparted by the IE to the NE were further tested practically when the NE were together with the responsible factory persons putting the activities further into practice. This can be described as participatory practical training with many reflection moments.

Additionally, (4) Factory floor demonstrations for instance in the case of hairsaving and

occupational safety and health (OSH) these were given in the tannery premises themselves.

(5) Several workshops were held. Invariable at the end of their mission IE would present their findings in workshop often attended by 30 –40 sometimes more participants. NE themselves would also convene workshops. Participants were tannery staff, sometimes owners and members of the various counterpart organisation KLC, UPLIA, STA, JTA etc.

In conclusion: UNIDO used a variety of training methodologies. These training methodologies had a high degree of practicals and were thus very well suited to the audience of adult learners.

International Expert National Experts / trainers

Tannery leather technologist, OSH, engineer in charge, management

1

2

2

2

Practical trials

3

3

3

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Annex 8: PHOTOS

SPV – hazardous waste management site

Record keeping at hazardous waste management site

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Photo: feeding of wet blue trimmings for “leather meal”

Current solid waste management conversion – unlikely to be sustainable

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Debriefing meeting with industry representatives

The UASB at Jajmau

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Final treated effluent from Jajmau (“domestic” sewer treatment plant and the “UASB” receiving a mixture of tannery and domestic effluent)

Current solid waste management conversion (Jajmau)– unlikely to be sustainable