casestudy-ceramic industry.pdf

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ETIV EMAS Technical Implementation and Verification Page 1 of 80

CASE STUDY Implementation of EMAS in Ceramic Industry

General data on the case study

TABLE OF CONTENTS

1 INTRODUCTION.............................................................................3

1.1. OBJECTIVES .........................................................................................................3

1.2. KEY EMS CONCEPTS .........................................................................................3

1.3. SUMMARY OF THE CASE STUDY................................................................... 4

1.4. GENERAL DESCRIPTION OF THE COMPANY ............................................51.4.1 Maronagrs (Margrs) .................... ...................... ...................... ...................... ..................... ... 61.4.2 Sanindusa 2.................... ...................... ..................... ...................... ..................... ..................... 7

1.5. BENEFITS OF EMAS............................................................................................8

1.6. DRIVING FORCES................................................................................................9

2 EMAS IMPLEMENTATION...........................................................10

2.1. CHARACTERISATION OF THE ACTIVITIES DEVELOPED.................... 102.1.1 Maronagrs ..................... ...................... ...................... ...................... ...................... ................ 10 2.1.2 Sanindusa 2.................... ...................... ..................... ...................... ..................... ................... 14

2.2. EMS SCOPE .........................................................................................................17

2.3. ENVIRONMENTAL REVIEW DIAGNOSTIC................................................17

2.4. ENVIRONMENTAL POLICY............................................................................18

2.5. ENVIRONMENTAL ASPECTS ......................................................................... 21 2.5.1 Identification of the environment aspects in Maronagrs ................... ...................... .............. 22 2.5.2 Identification of the environment aspects in Sanindusa 2................. ........................ .............. 27 2.5.3 Keep the information current. ....................... ...................... ....................... ...................... ....... 33

2.6. LEGAL AND OTHER REQUIREMENTS........................................................33 2.6.1 Identification and maintain up-to-date... ....................... ...................... ....................... ............. 33 2.6.2 Other requirements ................... ...................... ...................... ...................... ...................... ...... 342.6.3 Legal requirements distribution and other requirements............... ........................ .................. 34 2.6.4 Applicable legislation ..................... ...................... ...................... ...................... ...................... 35

2.7. OBJECTIVES AND TARGETS .........................................................................36

2.8. ENVIRONMENTAL MANAGEMENT PROGRAM .......................................37

2.9. DEFINITION OF STRUCTURE AND RESPONSIBILITY............................41

2.10. TRAINING, AWARENESS AND COMPETENCE........................................44

2.11. COMMUNICATION..........................................................................................45 2.11.1 Internal communication ...................... ...................... ...................... ...................... ................ 452.11.2 External communication..................... ...................... ...................... ...................... ................ 46

2.12. DOCUMENTATION AND DOCUMENTATION CONTROL .....................47

2.12.1 Documentation ..................... ...................... ...................... ...................... ...................... ........ 47


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2.12.2 Documentation control .................... ...................... ...................... ...................... ................... 51

2.13. OPERATIONAL CONTROL............................................................................54

2.14. EMERGENCY PREPAREDNESS AND RESPONSE....................................55

2.15. MONITORING AND MEASUREMENT ........................................................ 57

2.16. NONCONFORMANCE AND CORRECTIVE AND PREVENTIVEACTION...........................................................................................................................62

2.17. RECORDS...........................................................................................................63

2.18. EMS AUDIT ........................................................................................................64

2.19. MANAGEMENT REVIEW...............................................................................66

2.20. ISSUES TO BE ADDRESSED BY ORGANISATIONS IMPLEMENTING

EMAS 662.20.1 Legal compliance.......... ...................... ...................... ...................... ...................... ................ 662.20.2 Performance.............. ..................... ..................... ...................... ..................... ....................... 67 2.20.3 External communication and relations.................... ....................... ...................... ................. 70 2.20.4 Employee involvement ...................... ...................... ...................... ...................... ................. 71

2.21. ENVIRONMENTAL STATEMENT ................................................................71

2.22. VERIFICATION................................................................................................. 72

2.23. REGISTRATION ...............................................................................................722.23.1 Implementation....................... ...................... ...................... ...................... ...................... ...... 722.23.2 Verification and validation ..................... ...................... ..................... ...................... ............. 73

2.23.3 Register................ ...................... ...................... ...................... ...................... ..................... .... 73

3 CONCLUSION..............................................................................74

3.1. MAIN DIFFICULTIES ........................................................................................74

3.2. ENVIRONMENTAL IMPROVEMENTS ACHIEVED and EXPERIENCECOLLECTED.................................................................................................................. 75

3.2.1 Maronagrs ..................... ...................... ...................... ...................... ...................... ................ 75 3.2.2 Sanindusa 2.................... ...................... ..................... ...................... ..................... ................... 77

3.3. CONCLUSIONS ...................................................................................................79

4 ANEXES .......................................................................................804.1. Annex 1 Panning ................................................................................................80

4.2. Annex 2 Implementation and operation (Do): ................................................80

4.3. Annex 3 Checking and corrective action (Check):..........................................80

4.4. Annex 4 Management Review (Act):................................................................80


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1 INTRODUCTION

The main objective of CTCV work on this project is to produce a manual based on the Community eco-management and audit scheme (EMAS) implementation in the ceramic industry.

These Case studies include a general description of EMAS implementation process, with special focus onthe issues that are more relevant in the ceramic industry.These study case manual was prepared by the Portuguese Technological Centre for Ceramic and GlassIndustry (Centro Tecnolgico da Cermica e do Vidro) CTCV, Dipl. Ing. Marisa Almeida and it includes 3main parts. The first one describes in general the ceramics industries (tile and sanitary ware), the second onefocus on the implementation of the EMS (environmental management system) according to EMAS regulation(Community eco-management and audit scheme) in those industries. Finally it is highlighted theenvironmental improvements achieved by the company (results, benefits) and the main difficulties founds.

1.1. OBJECTIVES

The objective of this document is the development of "case studies" manual as a guideline for the ceramicindustry sector to support for the EMAS implementation, and thus promoting and facilitating the registrationof these sector activities, in order to achieve an improved environmental performance.

This Case study includes a general description of the implemented environmental management system(EMS) and some examples of good practices, documentation and procedures for the ceramic specificenvironmental characteristics, taking in account the significant aspects and impacts of the developed activity,legal requirements and the main relevant conclusions achieved by the organizations.

1.2. KEY EMS CONCEPTS

The basic steps/elements associated with the implementation of an EMS according to EMAS and ISO

14001:1996 follows a Plan-Do-Check-Act (PDCA) management model, also called the Deming or PDCAcycle (Plan, Do, Check, Act), focus on the continuous improvement cycle.

Once the EMS is implemented, the organization will develop continuous improvement cycles, repeating theprocess and increasing the level of environmental performance.

The continuous improvement of environmental performance is defined at EMAS Regulation as: theprocess of enhancing, year by year, the measurable results of the environmental management system relatedto an organizations management of its significant environmental aspects, based on its environmental policy,objectives and targets.

The steps of EMS implementation considered in this case study for the different phases of the continuousimprovement cycle, are:

Planning (Plan): Environmental review diagnostic; Identify Environmental Aspects and impacts (see A.3.1 of EMAS II); Identify and maintain up-to-date legal and other Requirements (see A.3.2); Establish Objectives and Targets (see A.3.3); Develop an Environmental Management Program (see A.3.4) and use performance indicator (see B.2).

Implementation and operation (Do): Definition of structure and responsibility and provide adequate resources (see A.4.1); Training, awareness and competence (see A.4.2); Establish internal and external communication (see A.4.3); Create and maintain EMS documents (see A.4.4); Documentation control (see A.4.5); Establish and maintain operational control (see A.4.6); Emergency preparedness and response (see A.4.7).


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Establish the infrastructure to operate the EMS system (in both ceramic industries it was integrated withother management systems); Participation of employee including the detection of failures and improvements of environmentalbehaviour, operation control, training (encourages and motivates); Communication with all interested parties, in order to assure the knowledge and participation in theenvironmental system; To monitor and measure environmental parameters and develop procedures and work instruction thatmeet the requirements of EMAS II, and take corrective actions; Top management review to improve the EMS performance.

Conclusions present the environmental improvements achieved by the ceramic companies through the EMASimplementation. Benefits include a better knowledge and control of the organization environmental impactsof its activities, products and services, better assure compliance with applicable legal and other requirementsand a continuous improvement in environmental behaviour.The main difficulties found in the EMAS implementation in the ceramic industries are also point out, andthey refer mainly to the gaseous emissions aspects and noise.

EMAS is a strategic and systematic management tool for environmental issues.

1.4. GENERAL DESCRIPTION OF THE COMPANY

The Ceramic Industry involves the transformation of argillaceous inorganic raw materials by firing them inorder to obtain several ceramic materials.Portugal possesses a rich soil in amount and quality of a great part of the raw materials used in the ceramicindustry. Therefore, the Ceramic Industry represents a traditional and prominent sector at national level.This sector produces a wide range of important products from the sanitary ware to the construction industry(e.g. bricks) and include long life cycle, wear resistance, chemical inertness and low toxicity, fire and heatresistance.Among these sub sectors it was selected two companies, one of the sub sector of the wall/floor tiles(Maronagrs) and another of the sanitary ware (Sanindusa 2).In what concerns the wall/floor tiles company, it is already certified for ISO9001:2000, concluding the

development of its integrated system of Quality and Environment, foreseeing its register in the EMAS in thefirst trimester of 2005. In what concerns the sanitary ware company, it is implementing an integrated systemof Quality, Environment and Health and Safety, foreseeing its register in the EMAS in the first semester of2005.


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Figure 1 - Location on the study-case ceramic companies

1.4.1 Maronagrs (Margrs)

The company is devoted to the production and commercialisation of products of ceramic floor, whatcorresponds to a C.A.E. 26302 - Production of tiles, mosaics and ceramic plates.Maronagrs was founded in 1981, being one of the first six industrial units to produce porcelain stoneware inthe word.In 2000 Maronagrs invest in the production of multiple types of products formats (from 20cmX20cm to60cmX120cm), special pieces and formats, being one of the best in the sector.In October 2002 PANARIA group acquired Maronagrs, being one of the biggest ceramic tiles producer. ThePANARIA group has more three ceramic industries located in Italy - EMLIA ROMAGNA (Finale Emilia,Toano e Fiorano Modenese). The PANARIA Group has more than 1000 employees.Margres is the mark of the product.Site: www.maronagres.pt


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LocalizationIt is located in Chousa Nova lhavo, district of Aveiro in a land with a total area of 60 031 m 2, of whichabout 24 819 m2are covered.Maronagrs is working in an area where there are several industrial units and houses in its immediateproximity (West and South). To North and West it faces agricultural lands and some houses. To South andSouthwest it faces the municipal route. To East it faces a hydraulic ditch and agricultural lands.

FunctioningIn general terms, the sections of preparation of raw materials, pressing and kilns are run on shift workuninterruptedly in three rotative shifts during the whole day. The workers can choose one of the three shifts,although only during 2 of the shifts (the day and night shifts) all the equipments and personal affect areworking. The polishing section is run on 3 rotative shifts from Monday to Friday.Usually, it stops working in August or September.

Number of workersThe company has 180 workers distributed throughout the different sectors.

EnergyThe sources of energy in the company are electricity, natural gas and diesel oil.

Productive process

The company produces two types of products: porcelain stoneware and polished porcelain stoneware, whichare used as pavement and covering. The company is divided into different sections:

Body preparation and atomization; Pressing and Drying; Decoration; Firing; Sorting and packaging; Polishing.

1.4.2 Sanindusa 2

SANINDUSA was founded in August 1991. The construction of the industrial facilities began in February1992 and in May 1993 operations started with vitreous china production. Within a year, the company doubledboth production capacity and workers number.Shortly after, Sanindusa conquers market trust and consolidates its quality image. The next step in thecompanys strategy evolved naturally into an integrated product supply approach: the global bathroomconcept.In 1997, Sanindusa buys Grau taps and accessories factory. Production begins two years later, completingour range of products, developing bathroom and kitchen single-lever taps and mixers along with othercomplementary products.In 1998 another industrial unit is launched producing plain and whirlpool bathtubs, shower trays and acrylicshower columns.In 2001 a new project stage begins, as products are oriented towards a more specific market segment:architects and interior designers. A fine fireclay production unit is created. This material allows a hugediversity in product range developing new technical and esthetic solutions.Again in 2001, the company begins its internationalization process opening its first subsidiary company:Sanindusa Spain. This way the company enters the Spanish state of affairs and social reality.Over the years, Sanindusa conquered an excellent brand image and the trust of its Clients thanks to itsenterprising determination and commitment. Success as become both an inspiration and a challenge to moveforward, betting in new techniques and developing information and innovation methods to improve ourrecognized service excellency.Sanindusa 2 was created in August 2000. Operation began two years latter, enduring vitreous china piecesproduction. This is an ambitious project and an example of technologic innovation in the sector. Sanindusaoptimizes the quality of final products recurring to state-of-the-art production processes, integrating globalmanagement and the rationalization of productive resources. Sanindusa S.A., can be proud of conquering on ashort period of time such a detached position on a sector dominated by strong groups of companies. The


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companys path discloses an even greater value since it is the largest company in this field operating in theIberian Peninsula with entirely national equity capital (source: www.sanindusa.pt).

SANINDUSA 2 is an industrial company dedicated to the production and commercialization of sanitary ware,which is classified with the code CAE-Rev. 2.1, 26220:

Group - 262"Production of ceramic products no refractory (except those destined for construction)and refractory";Subclass - 26220"Production of ceramic goods for sanitary uses."

The company was founded in August 2000 and its labour began in 2002.

LocalizationThe industrial facilities of the company are located in the villageTocha, municipality of Cantanhede, districtof Coimbra and are placed in an area classified in the Municipal Director Plan of Cantanhede as "IndustrialZone." They have the following immediate surroundings:

o North: another industrial unit, LACTOGAL;o South: ETAR (LACTOGAL station of treatment of waste water);o East: the access highway to the industrial zone followed by forest area;

o West: forest area.The industrial facility is implanted in a land with a total area of 52 652 m2.

Number of workersThe company has a total of 87 workers, of which 76 belong to the production section, 10 to the maintenance,1 to the administrative area. There are also 5 workers that belong to the management section.

EnergyThe sources of energy consumed by the company are electricity, GPL and diesel oil. The company began theconsumption of natural gas in April 2004 acquiring it to an autonomous unit of natural gas (LNG storagetank).

Productive processThe manufacturing process includes:

Body Preparation Preparation of glazing Forming; Drying Glazing; Firing; Sorting and packaging; Storage of final product

1.5. BENEFITS OF EMAS

An effective EMS can help an organization avoid, reduce or control the adverse environmental impacts of itsactivities, products and services and assist in continually improving environmental performance.The EU eco-management and audit scheme (EMAS) is stricter than ISO 14001 and a better communicationtool with the public and other interested parties.For each one of the companies some sensitization actions for the EMAS had been done.Having the EMAS allows the organization: to establish a environmental policy adequate to its proper reality; to identify the significant environmental aspects, the relevant legal requirements and the priorities, in

order to define adequate environmental objectives and targets; to establish a management system for the environment area, integrating it in the activity of global

management; to establish a structure and a program to implement the policy and to reach the objectives and targets; to facilitate the planning, the control, the preventive and corrective actions and the auditing and review

activities, in order to assure that the policy is fulfilled and that the EMS remains adequate;


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to define responsibilities, practices, processes and procedures for the establishment, accomplishment,revision and maintenance of the environmental policy;

to evaluate its environmental performance and to assure that this is not only in compliance with itsenvironmental policy, as thus it will go to continue; to demonstrate the conformity of its environmental performance with the requirements of the standard to

all interested parties; to have capacity of adapting to changing circumstances; awareness and motivation of all the staff of the organisation for environmental matters; to maintain a better relation with the interested parties (public community, government, etc) economic benefits from the implementation of EMAS; reducing incidents that result in liability; demonstrating reasonable care.

1.6. DRIVING FORCES

The main reason for the ceramic companies to implement the environmental management system accordingto EMAS were: To have a better eenvironmental profile; Improve environmental performance; Explore the market with green customers; Improvement in the market-competition; Financial benefit from national project (POE Plano Operational de Economia) to which both industriessubscribe; To assist with legislative compliance; To improve environmental management; To help identifying cost savings in resources (energy, water and raw materials) and waste management;

In the case of Maronagrs there was also a pressure from the international group that belongs Panaria, asthere is one company in Italia that is already register in EMAS.


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2 EMAS IMPLEMENTATION

In this part of the manual information and examples on the various steps of EMAS implementation ispresented. The following information is supplied:

Presentation of the EMAS II structure implemented; Main conclusions of the Environmental Review Diagnostic; Environmental Policy; Examples of Environmental Procedures, work instructions and other documentation;

Key tasks for managers developing, implementing or improving an EMS include the following (based on ISO14004): identify the environmental aspects, environmental legal requirements and other environmentalrequirements associated with the organization's activities, products and services; establish and maintain communication relations with interested parties; achieving environmental objectives and targets and evaluate environmental performance; provide appropriate resources, including financial, human, technical and training, to comply withenvironmental legal requirements and other environmental requirements to which the organization subscribes; ensure commitment with the environmental policy, legal requirements and environment protection ofmanagement and all persons working for or on behalf of the organization; establish a management process to audit and review the EMS and to identify opportunities forimprovement of the system and resulting environmental performance.

2.1. CHARACTERISATION OF THE ACTIVITIES DEVELOPED

The activities developed in the ceramic organizations can be summarized in following main groups: Industrial process (manufacture process) ; Maintenance; Laboratory; Offices; General activities.

Next a brief description of each process and developed activities and main inputs and outputs is presented.

2.1.1 Maronagrs

The ceramic tile manufacturing process consists of a series of successive stages, which can be summarised asfollows:- Raw materials preparation (body preparation);- Pressing and drying of the green body- Glazing;- Firing;

- Additional treatments- Sorting and packing


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Body preparation

Figure 2 - Spray drier

The used raw materials, clays (argyles) and feldspar, arestored in separate granary, being transported by a shovelloader to independent tolvas with load cells where theautomatic dosage is made by weight. So the proportioning ofraw materials is performed gravimetrically. The raw materialsare, then transported, through rugs transporters, to thediscontinuous mills of balls (type Alsing) and continuousmill, where it is added the water and the deflocculated. Then,it takes place the grinding. After this operation, the resultantsuspension (slip) is screened and stored in stirred storagetanks (with slow agitation).Simultaneously, in on-high inox tanks it is prepared a colourconcentrate with the subsidiary raw materials (glaze frits,fused, colouring natural oxides, inorganic colourings).The slip ,then, is mixed with the colour concentrate prepared

previously and simultaneously pumped for the feeding tank ofthe spray driers ( atomizer). Drying is performed attemperatures between 450 and 600 C, resulting the ceramicpowder with the appropriate characteristics to the followingoperation, the forming stage. The spray drier uses natural gas.

Pressing and Drying

The pressing processes of the power with hydraulic pressesforms the tile. The company possesses various lines for theforming and drying (Line Nassetti and line Sacmi).The pressing takes place in hydraulic presses of greatpotency. After pressing, operation in which the pieceacquires his form, the material is transported to the verticaldryer (there are 4 dryers, one for press) to reduce themoisture content. In the vertical dryers, the pieces are fedinto baskets consisting of several decks of rollers. The timeof drying is about 2 hours; the temperature of the drying airis about 160 to 180 C, warm by 1 or 2 burners fed bynatural gas.

Figure 3 - Hydraulic press

DecorationThe company possesses several (4) decoration lines, associated to the driers lines, in which takes place thedecoration applications, being also used as line of transport of the pressed material and dry for the loadmachine (LVG). The decoration takes place with the application of fine glazing layers for aerographer orusing the serigraphy method or other methodology. The application of decorations is sporadic.Glazing is done to provide the fired product with some technical and esthetical properties such asimpermeability, cleanability, gloss, colour, surface texture.Then the pieces remain in the storage park until they are unloaded into the roller kiln (LVG), to suffer firing.


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Firing

The firing takes place in one of the 2 roller kilns. The kilnsare about 104 meters in length, that reaches a maximumtemperature about 1200 C and the complete cycle of firingof 52 minutes. The employed fuel is the natural gas. Thefired material is, after leaving the oven, carried for palettesin iron, in which waits for the following operation.Each kiln possesses two chimneys, one of exhaustion andanother of cooling. Firing provide the tile characteristics asmechanical strength, dimensional stability, fire resistance,chemical resistance, cleanability, etc.

Figure 4 - Kiln

Sorting and packagingThe sorting of the final product depends on two types of defects: the visual defects, detected by the operatorsand the dimensional defects, calibers and flatness, detected by automatic equipments installed in the sortinglines and packaging. In the company sorting and packaging machines are installed, being the materialautomatically, separated in accordance with the sorting class it belongs to. The result is a controlled productwith regard to dimensional regularity, surface appearance and mechanical and chemical characteristics.Then, we have the packaging operation in card boxes and the subsequent placement of the boxes in woodpalettes. This sequence is totally automatic. The palettes are then transported in a stacker, belted with ribbonplastic, and plastic-coated with term-retractile plastic. After this operation the pieces palettes are sent to thestorage of the finished product.

PolishingA part of the fired product (porcelain tiles) is sent for the polishing section. The operation takes place inautomatic machines where the fired tile surface is polished to produce a shiny unglazed homogeneous tile(suffering wear and tear for friction of abrasives, whose grain is successively finer/thinner). At the end of theline the polished material is clean with water and dries with hot air, it is chosen and wrapped in card boxes.

Flowchart of the industrial process Next, it will follow the outline of the manufactured process, where it is indicated simultaneously the focusesof effluents emission.


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Drying

Firing

Storage

Sorting and

PackakingInputs

Outputs

Electricity Energy

Water

Liquid Effluent

Fugitive Emissions

Gaseous Emissions

Solid Waste

Packing Materials Moulds Colouring Deflocculant Raw Materials Glazes and Paints

Body Preparation

and atomization

Granulation

Pressing

Control of the

quality

Decoration

Thermal Energy

Figure 5 - Maronagrs process fluxogram


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The auxiliary facilities include: Maintenance Two industrial wastewater treatment plants - one for the wastewater from the polishing phase, and otherfor all the other wastewater produced in the factory; The quality control of the untreated and treated water iscarried out periodically (according to the permit) on the general wastewater treatment facility. Transformer stations for power network; Generator in case of electric energy failure; Exterior products storage area; Waste storage area; Laboratory it carries out a set of performance tests to the raw materials and to the final product.

The administration buildings (offices) provide the necessary logistical support for the production.

2.1.2 Sanindusa 2

The sanitaware manufacturing process consists of a series of successive stages, which can be summarised asfollows:- Body preparation;- Preparation of glazing;- Forming;- Drying;- Glazing;- Firing;- Additional treatments;- Sorting and packing.

Productive process:

Body PreparationThe main raw materials used in the production of sanitary ware dish are clays, kaolin (china clay), quartz,feldspar and calcium carbonate and other additive (talc, among others).In the case of Sanindusa 2, there is not a preparation of raw materials, since the slip casting (paste or claysuspension) used in the company is bought to external suppliers (SANINDUSA Aveiro), and it is transportedin tankers and directly unloaded into underground storage stirred tanks (agitated).The resulting wastes process (breaks of green product and drying) are diluted with water in an agitated tank,screening and then storaged. This mixture is ready to be used in the forming phase, by high pressure stuffing.

Preparation of glazingThe glazings are processed internally; the several raw materials used in this processing are acquired inpowder or suspension state. Its preparation involves gravimetrically operations (weighting) of raw materials(with aspiration system), wet grinding (mills of balls), screening, agitation and deferrization.

FormingThe slip casting goes from the storage tanks to the intermediate tanks by mechanical means and it is heatedup to 45C.The manufacture of the pieces happens by an automated process, of high pressure, with the followingoperations: stuffing of the mould, thickness, moulding, drying and removal of the mould.After the opening of the moulds the pieces are removed automatically and put in transporters where they willremain until they will be sent for the drying. This period allows a first drying of the pieces, providing themthe necessary mechanical resistance to its handling in the last stage.


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Drying

Figure 6 - Buffer

The drying operation takes place in a firstphase in the ambient air (buffer n. 1) andin a second phase in 2 intermittent fastdryers, using auxiliary burners initiallyGPL and after April 2004 the natural gasas fuel. A part of the production is not dryin the buffer, passing directly to the dryingin the fast dryers.After a 10 to 12 hours cycle, the piecesare removed of the dryer to a warehouse,by LGV, for following to be applied theglass.

Figure 7 - Drier

GlazingBefore they go to the glazing section the pieces go through avisual inspection and a last phase (in 5 inspection cabins).The dry products with no quality (waste) return to the sectionof preparation of pastes for being recycled again by thementioned process.The glazing of the pieces takes place in 2 glazing cabinsthrough last generation technologies, having recourse to therobotics and to a cabin of manual glazing. These cabins areprovided with effluent treatment (water curtain).

Figure 8 - Inspection cabin

After the glazing the pieces are automatically cleaned in the zone of the "freight". Continuously these pieceswill go for transport screen to be put into the tunnel kiln.

Firing

A tunnel kiln and an intermittent kiln are installed witha maximum temperature of firing of approximately1200C; they are fed since April 2004 on natural gas.

The glazed products are loaded into the tunnel kiln,with about 75 meters. The pieces are introduced withpulses that can oscillate between 12 and 18 minutes inthe tunnel kiln, in an approximate firing cycle of 28hours. The control of the firing is totally automatic,including temperature, pressure, state of the differentfans, and storage of the pieces data in manufacture.

Figure 9 - Tunnel kiln


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Sorting and packagingIn this sorting phase are made the choice operations (visual inspection), final finish and assembly ofmechanisms and components.In the packaging of the pieces it is used card boxes, white plastic ribbon, and the finally the material isinvolved in plastic.

Storage of final productThe final product are stored in height (shelves) and managed automatically in interior parks.

Flowchart of the industrial process

Figure 10 - Sanindusa 2 process fluxogram


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2.2. EMS SCOPE

The EMS scope is an important early step.Top management defined the scope and all activities, products and services of the organization within thedefined scope were included in the EMS.The scope is defined in the organization manual, and it includes all the organizations activities, products andservices. It includes the environmental aspects that it can control and those over which it can be expected tohave an influence.

The manual is integrated with quality (case of Maronagrs) and with quality and occupational health andsafety) in the case of Sanindusa 2.

2.3. ENVIRONMENTAL REVIEW DIAGNOSTIC

The aim of this environmental review diagnostic is to check the environmental aspects of the organizationsactivities, products and services as a basis for establishing its EMS.

The ceramic organizations conduct a review, as they have no previous EMS, although they haveenvironmental practices.To perform the environmental review diagnostic, the industries followed this strategy: Data on the organization (location, production information, raw materials and energy input); Environmental information:

Local conditions: geological, soil, atmospheric conditions (where available). Special focus wasgiven in Sanindusa, despite the fact that the location is an industrial zone, the surrounding area isforest zone;

Consumption data: raw material, water, energy; Emission data: emissions to air, emission to water, emission to land wastes, noise; Analyzing products, processes, to the identification of environmental aspects, including those

associated with normal operating conditions, abnormal conditions (includes shut-down, start-up andmaintenance), and emergency situations and accidents;

List of environmental legislation and other environmental requirement applicable to the ceramic industryincluding analysing sanctions, licenses and discharge permits; It was analysed on a first approach the keylegislation points and it was compared with the industry behaviour (eg. the ceramic industries performance onemission to air (dries chimneys, kiln chimney, others chimneys) was compared with the applicable nationalregulation for gaseous emissions (Portaria 286/93), It was also analysed the eventual failures of compliance(e.g. fluorine emissions). Compilation of existing environmental management practices and procedures including those with sub-contracting activities.- Analysis of accidents and emergency situations that may affect the environmental that have occurred (in thepast);- Evaluating the opinions of interested parties (eg. clients, subcontractors and local residents) Analysis of complaints from interested parties (local residents, official entities, etc )

The environmental review was conducted by:Maronagrs: compilation of several documents including: results of external diagnostic (performed byexternal entity), using checklists, process flowcharts including inputs and outputs, interviews, directinspection and the results of past and current measurement (gaseous emissions, water, wastewater, energy,noise, waste), results of previous diagnostic.Sanindusa 2: summarized environmental diagnostic performed by external entity (CTCV) that include massbalance, characterization of the local implementation, process flowcharts, results of current measurement(gaseous emissions, water, wastewater, waste, noise, energy), list of applicable legislation, list and analysis ofprevious accidents.The methodology used by external entity included visits, direct inspection, interviews to several collaboratorsand questionnaires to the main industrial responsibles, analysis of results of measurements (gaseousemissions, water, wastewater, waste, noise, waste), analysis of failures of compliance and sanctions. Analysisof licenses and discharge permits (water and wastewater).


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Main results from the Environmental Review Diagnostic include the following important environmentalaspects:

Energy consumption; Water consumption; Raw material consumption; Wastewater treatment (in the case of Maronagrs there are two wastewater treatment facilities, one

where the final effluent is complete recycled, and the other that treats the wastewater from processand needs improvement);

Noise (in the case of Maronagrs is important while in Sanindusa 2 is not so important); Waste; Gaseous emissions (importance of fluorine emissions typical from ceramic industry)

2.4. ENVIRONMENTAL POLICY

The EMAS requirement states:Top management shall define the organisations environmental policy and ensure that it(a) is appropriate to the nature, scale and environmental impacts of its activities, products and services;

(b) includes a commitment to continual improvement and prevention of pollution;(c) includes a commitment to comply with relevant environmental legislation and regulations, andwith other requirements to which the organisation subscribes;

(d) provides the framework for setting and reviewing environmental objectives and targets;(e) is documented, implemented and maintained and communicated to all employees;

(f) is available to the public.

The environmental policy establishes the principles of action related to the environmental performance of theorganization. The policy should be adequate to the environmental impacts of the organizations activities,products and services (within the defined scope of the EMS) and should guide the setting of environmentalobjectives and targets (ISO14004).

How to do it? How it was implemented?

The top managers of the two ceramic industries defined the environmental policy, after the results of theenvironmental diagnostic and it was based on the organization mission, vision, core values and beliefs. In thecase of Maronagrs it was integrated with the quality policy previous defined (Maronagrs have an qualitysystem certified according to ISO9000:2000). In the case of Sanindusa2 the policy was integrated with otherorganizational policies namely quality, occupational health and safety.

The environmental policy is published in the manual and it was communicated to all employees throughplacards.


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POLTICA DA QUALIDADE E AMBIENTEA Maronagrs, Comrcio e Indstria Cermica, S.A. tem por objectivo o crescimento dos seus negcios,atravs da satisfao das necessidades e expectativas dos seus clientes internos e externos assegurandoum crescimento sustentado e a remunerao justa do capital investido.

A responsabilidade pela qualidade e ambiente, pelo cumprimento da legislao ambiental e demaisregulamentos e requisitos aplicveis partilhada por todos os seus colaboradores, de acordo com oprincpio:

Fazer bem primeira, na altura certa, sempre!

Este princpio posto em prtica por todos, atravs do cumprimento dos procedimentos que dizemrespeito a cada um.

A Maronagrs, Comrcio e Indstria Cermica, S.A.:

Adopta um sistema de melhoria contnua dos produtos, dos processos e servios, em que todos osseus colaboradores se empenham directamente atravs da sugesto, anlise e implementao demelhorias, com o objectivo de reduzir os seus custos de produo e da no qualidade, minimizando o seuimpacte ambiental.

Compromete-se a uma melhoria contnua do seu desempenho ambiental recorrendo, sempre quepossvel e economicamente vivel, adopo das melhores tcnicas disponveis (MTDs), adequadas escala e dimenso dos seus impactes.

A preveno da poluio, a racionalizao de recursos naturais, a minimizao (e

valorizao) de resduos, o controlo das emisses gasosas e do rudo gerado

para o exterior, bem como a qualificao e motivao dos colaboradores

constituem eixos prioritrios de actuao da empresa.

Compromete-se a implementar, documentar, comunicar, rever e divulgar a sua poltica, objectivos edemais informaes pertinentes a todos os colaboradores e outras partes interessadas, procurandoenvolver no seu Sistema de Gesto parceiros, fornecedores, clientes e comunidade envolvente.

These policy states commitments to comply with several environmental areas:o Continual improvement of product, process and services with a minimal adverse environmental

impact;o environmental legal requirements and other environmental requirements to which the organization

subscribes;o prevent pollution; efficient use of resources, avoid and minimized (and valorization) the waste,

gaseous emissions and noise control;o continual improvement through the implementation of the best available technologies (BAT)

adequate to its environmental impacts;o employees qualification and motivation to act competently and responsibly;o documented, implemented, maintained and communicated , reviewed the policy, objectives and

other information regarding the Management System (quality and environment) to all employeesand other interested parties;

o involve interested parties like suppliers, clients and local community in the Management System(quality and environment)


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Poltica da Sanindusa

Qualidade, Ambiente e Sade e Segurana do Trabalho

A Poltica da Sanindusa Industria de Sanitrios, S.A. traduz com rigor aquilo que sentido pelaAdministrao e define as directrizes a seguir por todas as pessoas que colaboram na ou com a empresa.So Nossos Compromissos:

Satisfao das necessidades dos clientes Inovando e melhorando a Qualidade dos nossos produtos e servios e apostando no design ediferenciao a preos competitivos, aumentamos a confiana na empresa, contribuindo para a suafidelizao.

Respeito pelas pessoas Desenvolver racionalmente as melhores condies de higiene, sade e segurana do trabalho para osseus colaboradores.

Apostar na formao e responsabilizao como veculo para a integrao e satisfao dos colaboradores. Respeito pelo Ambiente Minimizar de forma sustentvel o impacte ambiental da organizao, nomeadamente atravs da reduodos seus resduos slidos, lquidos e gasosos. Em paralelo, promovem-se aces preventivas da poluio esensibilizao dos colaboradores para as melhores praticas ambientais.

Utilizao das melhores Tecnologias Utilizar as melhores tecnologias partilhando sinergias entre unidades fabris como forma de reforo daprodutividade, reduo de custos, aumento da rentabilizao e reduo dos impactes ambientais.

Melhoria continua de tudo o que fazemos Para acrescentarmos valor a todas as partes interessadas: clientes, fornecedores, colaboradores,accionistas e a comunidade envolvente.

Cumprir os requisitos das normasQualidade NP EN ISO 9001:2000Sade Segurana e Higiene no Trabalho NP 4397:2001Ambiente NP EN ISO 14001:1999 e Regulamento EMASbem como as exigncias legais e regulamentares aplicveisA Poltica da Qualidade, Ambiente, Sade e Segurana do Trabalho da Sanindusa revista sempre quedesajustada, divulgada em toda a Empresa e est disponvel a todas as partes interessadas.Sanindusa, 30 de Setembro de 2004

Pela AdministraoVtor Sampaio

A Poltica da Qualidade, Ambiente, Sade e Segurana divulgada em toda a Empresa e est disponvel atodas as partes interessadas.

This policy states commitments to comply with several quality, environmental and heath and safety areas.Special focus on continual improvement of product, process and services with a minimal adverseenvironmental.

The environmental policy is published in the manual and it was communicated to all employees throughplacard, and was distributed with wage and a calendar (2005). It is available to all interested parties.


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2.5. ENVIRONMENTAL ASPECTS

The EMAS requirement:The organisation shall establish and maintain (a) procedure(s) to identify the environmental aspects of itsactivities, products or services that it can control and over which it can be expected to have an influence, in

order to determine those which have or can have significant impacts on the environment. The organisationshall ensure that the aspects related to these significant impacts are considered in setting its environmentalobjectives.

The organisation shall keep this information up-to-date.

How to do it? How it was implemented?

The EMS begins with understanding how the ceramic organization can interact with the environment, andidentifying the environmental aspects that it can control and those which it can influence to determine theones that are most significative ones.

The environmental aspects are the elements of an organizations activities, products and services that caninteract with environment (see definition ISO 14004).

Direct environmental aspects aspects referring to the organization activity of which can becontrolled

Indirect environmental aspects aspects referring to activity of the organization, which can not befully controlled by the organization

The environmental impacts are the effect of the environmental aspects, that is, they are the changes in theenvironment, either adverse or beneficial, that result wholly or partially from environmental aspects (seedefinition ISO 14004).

The activities, products and services of both ceramic industries have effects on the environment byconsuming materials, energy and water and by discharging wastewater, waste, gaseous emissions and noise.

Environme ntal as pec ts

Wastewater

Energy

Water Production Gaseous emission (drying, firing)

Raw materials for ceramic body o f Emission to air: dust

Packaging materials Ceramic Noise

Auxiliary materials Materials Solid Wastes

Frit, Pigment and materials for glazes Waste Heat

Wastes

Traffic a nd Trans po rt

Ceramic Products

Figure 11 - Environmental aspects in ceramic industry


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The identification of the environmental aspects begun with an illustration of environmental aspects to theemployees (see Annex 1).Then the person responsible by each session has done a qualitative approach of the principal aspects on itsactivities.To identify and have an understanding of its environmental aspects, the organization collect quantitativeand/or qualitative data on the characteristics of its activities, products and services such as inputs and outputsof materials and energy, processes and technology used and facilities. The transports were subcontracted.

The Maronagrs procedure M PS-R06IT 00.01/03 - Identificao e Classificao dos Aspectos Ambientais,describes the methodology to identify and classified the significant environment aspects from the activities,product and services and their potential environmental impact (See Annex 1).Direct and indirect environment aspects have been considered.All the aspects were classified under normal, abnormal (shut-down, start-up and maintenance) and emergencyconditions.The activities include the process and the auxiliary (like maintenance, offices, ETAR, etc).Specially attention was given to past, on-going and planned activities.

The first step involve the definition of a functional team and the definition of the applicable criteria forevaluate the aspect and impact.The approach to identify environmental aspects was the process flow method, in which each activity wasindividually examined to identify associated aspects.This step involve the elaboration of the diagram process flow, identification of all activities related,identification of environmental aspects and impacts, evaluation the aspect and impact, and define the way tocontrol the environmental aspects. In figure 12 it is present the fluxogram describing the procedure used:

Documentary Analysis

Identification ofEnviro nmental Aspects

Criteria areRemained Valid

Classification ofEnviro nmental Aspects

Significant Analysis

Approval

Redefinition of

Criteria

Purchases

Customers

yes

no

Classificationare Remained

Valid

yes

no

Figure 12 - Maronagrs approach to identify and classify the environmental aspects


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The documentary analysis include the reports on the emissions, waste maps, monitoring of environmentalaspects.Auxiliary operations and facilities like maintenance, wastewater treatment (ETAR), offices, waste park,compressors, transport, food, construction, products were grouped for identification and evaluation ofenvironmental aspects, these approach was useful to help the ceramic industry to identified common orsimilar environmental aspects.

The environmental direct aspectswere:(a) consumption of water;(b) emissions to air (from chimneys);(c) emissions to air (from fugitive emissions);(d) releases to water (industrial liquid effluent);(e) releases to water (domestic effluent);(f) noise production;(g) waste production;

The environmental indirect aspectswere:

(a) consumption of energy (electricity);(b) consumption of natural gas;(c) consumption of ceramic raw materials and auxiliary;(d) consumption of other materials or resources;

Once the environments aspects and impacts were identified they were evaluated to establish the magnitude ofthe impact, and to determine their significance.The criteriaselected to classified the significance of the environmental aspects of its activities, products andservices, were according to requirement in Annex VI(6) of EMAS II and include: Size (scale) and severity of the environmental aspects that result on the gravity; frequency of the environmental aspects Fragility of environment Control Importance of stakeholders Legal issues: Enviromental legislation or other requirements to which the organization subscribesThe scale selected included 5 levels:

Level General description

1 Worst2 Bad3 Moderate4 Good5 Excellent


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The criteria selected for the environmental evaluation/classification were justified in a proper paper.

Criteria: SCALE SEVERITY GRAVITY CONTROLPROBABILITY/FREQUENCY

FRAGILITY OFENVIRONMENT

Stakeholder*

1 Intolerable Catastrophic Very critic Uncontrollable Very likelyExtreme risk to

ecosystem

Severalcomplaints

with NC

2 High Severe CriticExist but withdeficiencies

LikelyHigh risk toecosystem

Severalcomplaintswith no NC

3 Normal Moderate ModerateExist but with

somedeficiencies

Occasional Moderate riskOne

complaintswith NC

4 Low Mild Marginal Exist RemoteLow risk toecosystem

Onecomplaintswith no NC

5Very low notreportable

Harmless NoneExist and are

excellentUnlikely

No risk toecosystem

No complaints

* interested parties

For each environmental aspect the 5 levels of the criteria were adapted (see Annex 1).The criteria for indirect environmental aspects include:products and services, were according to requirement in Annex VI(6) of EMAS II and include: Fragility of environment; Probability of the environmental aspects; Gravity - Size (scale) and severity of the environmental aspects that result on the gravity; Control Importance of stakeholders Legal issues: Environmental legislation or other requirements to which the organization subscribes

Probability:

1. Continues - probability of occurrence more than once a day.2. Probable - probability of occurrence more than once a week3. Unlikely - probability of occurrence more than once a month;4. Not often - probability of occurrence more than once a trimester or semester;5. None

For the criteria: fragility, severity and control it was developed an index (IDA ndice de desempenhoambiental) to the suppliers, has the fragility, severity and control were directly in the suppliers. This IDA wascalculated based on a questionnaire and reflect the environmental impact of the aspect in the supplier.

Classification of environment aspects

The significant environment degree (S) is made by:

S = F (fragility) * P (probability) * G (G=gravity = severity*scale) * C (control) * I(Importance of stakeholders)

If S < 405, the impact is classified as significant or if there are legal issues applicable.

This evaluation is very important in order to identify the significant environment aspects and the objectiveand targets to be established.The report on the environmental aspects is stated on the document M PS-R06 FR 00.01, that is periodicallyup-dated, according to the procedure.

In the following figures it is presents the results of the environmental identification.


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Approval

Identification of aspects

environmental associates tothe activities, products and

services

Identification of environmental

impacts

Creation of criteria for

evaluation of environmentalaspects

Classification of the

environmental aspects

Manners of actuation for the

significant environmentalaspects

Register of the results of the

raising and classification inidentified folder

Divulgation of the significantenvironmental aspects

No

Yes

ApprovalNo

Yes

Figure 14 - Sanindusa 2 approach to identify and classify the environmental aspects

Direct environmental aspects include: emissions to air (from chimneys);s releases to water (domestic and industrial); production and treatment of wastes; use of natural resources and raw materials (including water, natural resources, electric energy and

fuel); local issues (noise, odour, dust, visual appearance, etc.); transport issues (both for goods and services and employees); risks of environmental accidents and impacts arising, or likely to arise, as consequences of

incidents, accidents and potential emergency situations;

Indirect environmental aspects include: product related issues (design, development, packaging, transportation, use and waste

recovery/disposal);

the environmental performance and practices of contractors, subcontractors and suppliers.


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* Indirect impact - The environmental aspect is originated by the supplier and the Sanindusa2 doesn't possessentirely control of administration.PI (Potential Impact) - Resultant potentials impacts of the activities of treatment of the emissions of Sanindusa2.

After the environments aspects and impacts were identified they were evaluated to establish the magnitude ofthe impact, and to determine their significance.The criteriaselected to classified the significance of the environmental aspects of its activities, products andservices, were according to requirement in Annex VI(6) of EMAS II and include: Size (scale); Severity; Fragility of environment; Control; Duration of the environmental aspects;

Legal issues: Enviromental legislation or other requirements to which the organization subscribes; Interested parties;

The scale selected included 4 levels:Level General description

1 Excellent2 Good3 Bad4 Worst

Environmental aspects Environmental impact Environmental aspects Environmental impactConsumption ofnatural resources andother

Reduction of naturalresourcesIndirect impact*

Consumption ofwater

Reduction of resourceshydricSaving of resourceshydric(recirculation)

Incidents, environmentalaccidents and potentialemergency situations

Atmospheric pollutionContamination of SoilsPI - Pollution of the soils, of thewater and of the air

Use ofnaturalresources,rawmaterials andother

Consumption ofenergy and fossilfuels

Reduction of resourcesIndirect impacts*

Emissions to air(punctual sources)

Atmospheric pollution

Mobil sources Atmospheric pollution

Production of wastes

PI- Pollution of thesoils, of the water andof the airValorization interns

Transportissues (rawmaterials andother) Fugitive

emissionsAtmospheric pollutionContamination of Soils

Environmental noise

Noise pollution

Domestic

PI - Pollution ofthe water and/orsoil

Subjects oflocal impact

Diffuse emissionsAtmospheric pollution

Discharge of liquid effluent

IndustrialContaminationof Soils


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1 2 3 4

Size (scale) Low Moderate High Very HighSeverity Harmless Marginal Severe Catastrophic

Fragility ofenvironment

No risk toecosystem orconfined zone

Low risk toecosystem Moderate risk

Extreme risk toecosystem

Control Exist and areefficient

Exist but they conbe improved

Exist but withdeficiencies

Dont exist

Duration (N) Sporadic Discontinuous Continuous (8

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