case studies implementation of emas in the cleaning material sector 1 etiv - emas technical...
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Case StudiesImplementation of EMAS in the Cleaning Material Sector
1ETIV - EMAS Technical Implementation and Verification 1
Project ETIV – EMAS TECHNICAL IMPLEMENTATION
AND VERIFICATION
Prepared by:
Case StudiesImplementation of EMAS in the Cleaning Material Sector
2ETIV - EMAS Technical Implementation and Verification 2
This project has been funded with support from the European Commission. This publication reflects the views only of the author, and the Commission cannot be held responsible for any use which may be made of the information contained therein.
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Objectives
ETIV Project
• Development of didactical training material to promote, stimulate and support the implementation of EMAS II Regulation
Case Study
• Supply information on EMAS implementation in a Cleaning Materials Producer, representing a “Case Study” on EMAS implementation
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Contents of this case study
Implementation of EMAS in the Cleaning Materials Sector
Company
Knud E. Dan A/SGreve, Denmark
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Company Description
• Danish Ltd. company• Founded 1960• 20 employees• Mixes and bottles cleaning materials• Yearly production: 1900 tonnes, sold in
Denmark and exported
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BoardBoard
ManagementRepresentativ
e
ManagementRepresentativ
e
AuditorAuditor
Production Manager
Production Manager Purchase
Assistant
Purchase Assistant
Office Assistants
Office AssistantsSales
Consultant
Sales Consultant Purchase
Assistant
Purchase Assistant Production
Assistants
Production Assistants Storage
Assistants
Storage Assistants
Office Manager
Office ManagerStorage
Manager
Storage ManagerSales
Manager
Sales Manager Chemistry
Manager
Chemistry Manager
Organisation diagram
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Production processes
Main processes are mixing of products from premixed raw materials, and bottling in to various containers
Production diagram
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Production diagram
DispatchDispatch
StorageStorage
BottlingBottling
Mixing raw materials
Mixing raw materials
Packaging material storage
Packaging material storage
Raw materials storage tanks
Raw materials storage tanks
Receiving raw material
Receiving raw material
Receiving new packaging material
Receiving new packaging material
Receiving used packaging material
Receiving used packaging material
Cleaning packaging material
Cleaning packaging material
Packaging material storage
Packaging material storage
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Certificates:
• Knud E. Dan holds both quality and environmental certificates:
ISO 9001 ISO 14001 EMAS
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Reason for introduction of EMAS
• Company wanted an ”Environmental Profile”• Wanted to be stronger on the market with
”green customers”• ”Environmental Statement” useful
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The implemention process
• Geographical demarcation: the production site only, sales division in other part of country not included
• Working environment included in system
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1. Environmental Policy
Combined quality and environmental policy
• … identify and minimize potential factors that may cause damage / harm to the environment ...
• … , chemicals and substances are replaced with less polluting through continuous product development …
• … continuous improvements …
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Structure of the EMS
• Company structure / foundation• Procedures / Flow diagrams (Process
descriptions)• Descriptions / basic information• Document for analysis• Tables• Tools
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Person responsible for document
Company logo
Version Document users Document number Document
approved by … and date
Document name (when printed the document is not under document control)
Simplified level indication
Document control
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Management system is computerised. Document access is possible through graphical interface and more traditional documents listings
Computerised EMAS
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All envrionmental impacts are listed
Raw materials
Packaging material
Water
Electricity
Gas
Fuel
Products
Packaging materials
Refuse
Wastewater
Emission
Heat
Knud E. Dan A/S
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Environmental impacts at Knud E. Dan (consumption)
• Raw materials (chemical substances)• Water• Electricity• Gas• Packaging• Fuel
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Environmental impacts at Knud E. Dan (outgoing)
• Chemicals for collection• Refuse for collection• Emmissions to atmosphere
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Working environment is also included
• Lay out of working stations• Time pressure• Stress• Working pace
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Prioritisation of environmental impacts
• The largest impacts happens at the customer• Packaging material: PVC bottles replaced• Informing customers how to dispose products
and packaging
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Objectives and targets
• Evaluated every year• Objectives linked to actual measurable targets• Periodical updating of targets ensures
continous improvement
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Examples of targets
• Chemical waste diminished from index 68 to index 65
• Gas usage must not exceed index 95• Electricity consumption maintained at index
120
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Lessons learned regarding objectives and targets
• It is important to see results from the start• Therefore: ”pick the easy options first!” – that is
areas with potential for improvement. At Knud E. Dan these were:
Packaging material (PVC replaced - huge effect) Electricity (very likely to give results if no efforts have
been made before. Financial gains also very likely)
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Data avaliability
• Data availability may be a problem (data sheets on raw materials)
• Information and measurements must be collected from various sources on various times
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Data monitoring must be well organised
• It may be difficult to: Obtain exact data Get data from correct period of time Obtain comparable data
• Knud E. Dan chose to monitor every month and use the financial year as overall period
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Goals and resultsEnvironmental impact Goal Measurement in
2002-2003
Raw material labelled “poisonous” (“T”) 20 18
Raw material labelled “dangerous for health”* 60 60
Electricity 120 130
Gas** 95 89
Chemical waste 40 72
Waste re-use (degree of) 15 19
Fuel consumption*** 17 16.6
Fraction of Environmentally labelled products
(“Svanemærket” issued by the Nordic Counsel)
43.9 53.5
Employee satisfaction 50 90
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Other improvements and results:
• Possibility of quick follow-up on consumption and other fctors going beyond expected values
• Good understanding and better control of company
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Examples of Environmental Management Programmes
• Substitution of cationic tenside by one third• Reuse of rinsing water from certain products• Substitution of PVC packaging• Reduction of harmful raw materials by
substitution• Materials for trays and cartons for packing of
productis must be recycleable
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Structure and responsibility
• Environmental manager is responsible for the bulk of the management system procedures
• Other employees responsible for daily working routine instructions
• Management groups for main areas: Production Storage Buying / expedition Sales
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Training, awareness and competence
• All employees trained at introduction of system• Training by doing works well• Employee skills are registered in employee
registrations records
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Communication with community and other interested parties
• Website with information on company• Environmental satatement available on website
– updated every year• Strict procedures in-house tell who is
authorised to communicate with the press
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EMS internal environmental audit
• Performed by different audit teams for different areas
• Audit teams are trained in audit and EMS• Audits are performed using audit checklists
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Management review
• Performed by management and middle management
• Performed yearly – but more often if necessary (special projects)
• Environmental projects and non-conformances are evaluated
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Internal gains of EMAS
• Powerful tool in company management• Environmental improvements• Some economic savings
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External gains of EMAS
• Knud E. Dan was expecting more sale, but it has only had limited effect
• EMAS symbol is used for marketing
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Overall evaluation of EMAS at Knud E. Dan A/S
• EMAS has helped the company organise itself internally
• EMAS has made the company more environmentally friendly
• EMAS has made the company save on energy and raw materials
• EMAS has provided a certified environmental statement