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ISO 14001:2004 AND OHSAS 18001:2007
COMPLIANCE STATUS REPORT
OF
BATTERY SUPPLIERS AND RECYCLERS OF
IDCOL SHS PROGRAM
March, 2014
Prepared by
Infrastructure Development Company Limited
2
1. INTRODUCTION
Infrastructure Development Company Limited (IDCOL) is committed to comply with required
environmental and social safeguards. It has adopted an Environmental and Social Safeguards
Management Framework (ESMF) of for its solar home system (SHS) program. According to this
ESMF, all approved battery suppliers in IDCOL SHS program have to be ISO 14001:2004 and
OHSAS 18001:2007. ISO 14001:2004 is an internationally recognized standard about
environmental management and OHSAS 18001:2007 is worldwide accepted standard for
maintaining occupational health and safety aspects. The basic requirements of these two
standards are mentioned in Annex –1 of Appendix -A. There are 17 battery suppliers of which
16 are local and the remaining one is Japan Solar Tech, which sells imported batteries. In
addition, there are three en-listed expired battery recyclers in IDCOL SHS Program, who also
require to be ISO 14001:2004 and OHSAS 18001:2007 compliants. These requirements are in
addition of the requirements of the Department of Environment, Bangladesh.
To assess the status of implementation of environmental and occupational health safety
management system, the respective official of IDCOL half-yearly visits all three recycling plants.
In case of battery manufacturing plant, there is a requirement to monthly visit. Based on the
primary findings and secondary information as are provided by the battery manufacturers and
recyclers, this Compliance Status Report has been prepared.
2. OBJECTIVES
The objectives of this compliance status Report are as follows:
To assess the commitment of management of manufacturers and recyclers about
environmental and occupational health safety sytem;
To assess the availability of required infrastructure like ETP and ATP;
To assess the status of documentation of required guidelines;
To assess the availability of medical facility;
To assess the gap in respect of the actual scenario and desired level;
To assess the areas where relevant stakeholders can support the recyclers and
manufacturers to implement environmental and occupational health safety system in a
satisfactory manner.
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2. LOCATION AND AREA OF BATTERY MANUFACTURING PLANTS
Among the aforesaid 16 (sixteen) battery suppliers, 13 battery suppliers have their battery
manufacturing factories in Dhaka Division, two are in Khulna Division and only one is in Sylhet
Division. HAMKO Battery has the largest battery manufacturing and recycling plant in respect of
area (an area of about7.5 acres) and scale of production But the smallest manufacturing unit is
owned by Z by A Corporation (an area of about 0.05 acre). In the following Table 01, the
location and area of the factory of 16 battery suppliers are provided.
Table 1: Location and area of battery manufacturing and recycling plants
Battery supplier Location of factory Area in acre
Rahimafrooz Accumulators Ltd.
West Panisail, Zirani Bazar, Gazipur 4.00
Panna Batteries Ltd. West Rasulpur, Kamrangir Char, Dhaka-1211 6.50
HAMKO Batteries Ltd. BSCIC I/A Shiromoni, Khulna 7.50
Electro Batteries Co. Ltd.
Boro Rangamatia, Durgapur, Ashulia, Savar, 5.00
Rimso Batteries Ltd. Plot#21, Kadamtoly Road Shyampur I/A, Dhaka-1204 0.20
Euro Battery Varardi, Kachkura Bazar, Uttar Khan, Uttara, Dhaka-1230
0.50
Z by A Corporation 403-404, Tejgaon I/A, Dhaka-1208 0.05
White Products Ltd. Plot 1142-1143, Nowjore, Gazipur 3.30
ECO Batteries Ltd. Uzilab, Sripur, Gazipur 1.00
JCo. Batteries Ltd. Plot no. S-6 , BSCIC I/A , Ruhitpur, Keranigonj, Dhaka. 0.25
Navana Batteries Ltd. CDA Plot No. – 3(P) & 4(P), Fouzderhat I/A, Chittagong
3.80
SunTec Batteries Ltd. BSCIC I/E, Khadimnagor, Sylhet 0.25
Gel Tec Batteries Ltd. Raj Fulbaria, Savar 0.20
Tamim Batteries Ltd. 111, Pobahati Road, Jhenidah-7300 1.20
A&P Batteries Ltd. Chaparbandh (Adampur), 2nd gate to Sonargaon Museum Road, Sonargaon, Narayanganj
0.75
Confidence Batteries
Ltd.
Brahmmanbagh, Mohajampur, Narayanganj 3.00
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3. PRODUCTION PROCESS
The production process of lead-acid battery in respect of required materials, basic chemistry
and manufacturing steps are briefly described in the following sections.
Required materials
For manufacturing a lead-acid batteries a number of materials are required including Sulfuric acid, Lead (red, pure, antimonial) Acrylic fiber, Carbon black, Expander, TK Oil and so on. The requirements of these materials varies with the capacity of batteries. In the following Table 02, a list of major materials are presented in respect of various capacity of batteries.
Table 02: Location and area of battery manufacturing and recycling plants
Sl. No.
Materials Capacity of battery in AH 30 55 80 100 130
01 Red Lead 0.5 kg 0.90 kg 1.30 kg 1.90 kg
2.80 kg
02 Pure Lead 3.8 kg 6.2 kg 8.7 kg 11.6 kg
14.0 kg
03 Antimonial Lead
4.5 kg 8.0 kg 10 kg 11.5 kg
11.7 kg
04 Sulfuric Acid 6.6 L 8.0 L 11 L 13 L 15 L
Source: Informal (Engr. Sahhidul Islam, Engineering Complex Limited)
Basic Chemistry
The basic chemistry of lead-acid battery is mainly the chemical reaction among lead di-oxide, lead and sulfuric acid as is depicted in Figure 01.
Figure 01: Basic chemistry of lead-acid battery
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Battery manufacturing process
Manufacturing of a lead-acid battery includes a number of steps as are shown in the following Figure 02.
Figure 02: Manufacturing process of al lead-acid battery
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3. BRIEF DESCRIPTION OF MANUFACTURING PLANTS
A brief description of IDCOL en-listed battery manufacturing plants is provided in the following section in light of some relevant parameters.
Number of Workers
At present the highest number of workers is operating in Panna Batteries Ltd (585). Thereafter, it is HAMKO and Rahimafrooz having about 500 full time workers. The detail list of workers in terms of gender is provided in the following Table 03. In case of Rahimafrooz, HAMKO and Panna Battery Ltd. the number of workers include both manufacturing plant and recycling plant
Table 03: Number of workers based on gender
Factory Number of staff Total Male Female
Rahimafrooz Ac. Ltd. 500 500 -
Panna Batteries Ltd. 585 550 35
HAMKO Batteries Ltd. 500 470 30
Electro Battery Co. Ltd 230 230 -
RIMSO Battery 150 130 20
Z by A Corporation 30 30 -
Euro Battery Ltd. 54 52 2
White Products Ltd. 202 201 01
ECO Batteries Ltd. 33 33 -
JCo. Batteries Ltd. 33 25 8
Navana Batteries Ltd. 220 220 -
SunTec Batteries Ltd. 177 167 10
Gel Tec Batteries Ltd. 38 37 1
Tamim Batteries Ltd. 45 45 -
A&P Batteries Ltd. 77 72 5
Confidence Batteries Ltd. 330 330 -
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Capacity of production
At present the highest number of battery is manufactured by HAMKO Battery. Their monthly production is about 70,000. But in consideration of manufacturing the solar batteries, it is Panna (30,000). The production of battery and the amount of required lead is depicted in the following Table 04 as is collected informally.
Table 04: Average monthly production and required lead
From the above Table 04, it is difficult to correlate with the quantity of required lead and quantity of battery production. Because different suppliers produce battery of varying capacity requiring different capacity of lead as is depicted in Table 02. In addition, the use of automatic technology is another factor to determine the amount of required lead. All of the battery suppliers were found to use manual and semi-automatic process except Rahimafrooz, Panna, Sun Tec, Electro and HAMKO Batteries. Their manufacturing plant seems to be mostly automated. But the most satisfactory automated technology has been observed in Confidence Batteries Ltd.
Factory Type of battery production
Average total Production /month
Production of solar battery/month
Required lead/month
Rahimafrooz Ac. Ltd. Solar, easy bike and IPS
40,000 15,000 450
Panna Batteries Ltd. Solar, auto and easy bike, IPS
65,000 30,000 750
HAMKO Batteries Ltd. Solar, auto, easy bike, auto, IPS
70,000 20,000 1000
Electro Battery Co. Ltd Solar 5,000 5,000 90
RIMSO Battery Solar, IPS 8,000 6,000 110
Z by A Corporation Solar 500 500 10
Euro Battery Ltd. Solar 3,000 300 50
White Products Ltd. Solar, Auto 6,000 2,000 120
ECO Batteries Ltd. Solar, IPS 1000 750 25
JCo. Batteries Ltd. Solar, IPS 2,500 2,000 40
Navana Batteries Ltd. Solar, IPS, Auto 30,000 4,000 275
SunTec Batteries Ltd. Solar, IPS, easy bike, rickshaw, auto
9,500 500 150
Gel Tec Batteries Ltd. Solar 1,000 500 20
Tamim Batteries Ltd. Solar 1,000 1,000 26
A&P Batteries Ltd. Solar 5,000 5,000 60
Confidence Batteries
Ltd.
Solar, IPS, easy bike, rickshaw, auto
30,000 10,000 450
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Among the 16 battery suppliers Rahimafrooz, Panna, HAMKO, RIMSO, A&P, White Products,
J.Co, Sun Tec and Gel Tec have female staff, of which mostly are engaged in low labour
intensive areas like filling, pasting. In addition, in a number of plants , female staff were found to
work in kitchen and dining.
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4. ISO 14001: 2004 AND OHSAS 18001:2007 COMPLIANCES
The ISO 14001:2004/2005 and OHSAS 18001:2007 compliance status in terms of certification
agency, date of issuance and expiration of 16 Battery manufacturing plants are mentioned in the
following Table 05.
Table 05: List of accreditation agency in respect of battery manufacturing plant
Battery supplier
Accreditation agency Accreditation issue date Accreditation validity date
Parent Subsidiary
ISO 14001:2004
OHSAS 18001:2007
ISO 14001:2004
OHSAS 18001:2007
Rahimafrooz Ac. Ltd.
IAF
Bureau Veritas 28 Jun 2010 15 Sep 2011 27 Jun 2013 13 Jun 2014
Panna Batteries Ltd.
AJA 6 Jul 2011 1 Nov, 2010 31 Oct, 2013
6 Jul 2014
HAMKO Batteries Ltd.
ANAB SAI Global 18 Jan 2012 22 Dec 2011 15 Jan 2015 22 Dec 2014
Electro Battery Co. Ltd.
IAF ISOQAR 5 Mar 2012 5 Mar 2012 5 Mar 2015 5 Mar 2015
Rimso Battery AJA 7 Dec 2011 6 Jan 2012 23 Sep 2014 6 Jan 2015
Euro Battery Ltd.
URS 13 Jan 2012 13 Jan 2012 12 Jan 2015 12 Jan 2015
Z by A Corporation
AIAO BMQR 22 Dec 2011 22 Dec, 2011 21 Dec, 2014
21 Dec 2014
White Products Ltd.
DNV 17 May 2011 17 Dec 2011 17 May 2014
16 Dec 2014
ECO Batteries Ltd.
URS
17 Sep 2013 17 Sep 2013 16 Sep 2016 16 Sep 2016
JCo. Batteries
Ltd.
AJA 1 Feb, 2012 4 Jun, 2012 28 Jan 2015 4 Jun, 2015
Navana
Batteries Ltd.
Bureau Veritas 27 Mar 2012 2 Jul 2012 26 Mar 2015 01 Jul 2015
SunTec
Batteries Ltd.
AJA 9 Oct 2012 7 Oct 2012 2 Oct 2015 7 Oct 2015
Gel Tec
Batteries Ltd.
Care Certification
24 Mar 2012 24 Mar 2012 23 Mar 2015 23 Mar 2015
Tamim
Batteries Ltd.
AIAO BMQR 18 Jun 2012
19 Jun 2012 18 May 2015
19 May 2015
A&P Batteries
Ltd.
IAF AJA 23 Dec 2012 23 Dec 2012 22 Dec 2015 22 Dec 2015
Confidence
Batteries Ltd.
DAS Certification
15 Jan 2014 15 Jan 2014 14 Jan 2017 14 Jan 2017
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5. MEDICAL FACILITY
It is appreciable that the battery manufacturers and recyclers aware about the medical facility of workers. All battery manufacturers have arranged weekly medical check-up facility except Gel Tec, ECO and Z by A Corporation. Z by A has arranged monthly check-up facility. ECO Batteries and Gel Tec are in the process of engaging doctor.
Table 0 6: Arrangement of medical facility
Battery supplier Arrangement of Medical Facility
Medicine facility
Rahimafrooz Ac.Ltd. Two times per week medical check-up
All medical facility
Panna Batteries Ltd. Weekly Basic medicine
HAMKO Batteries Ltd. Weekly Basic medicine
Electro Battery Co. Ltd.
Weekly
Basic medicine
Rimso Battery Ltd. Weekly
Basic medicine
Euro Battery Bi-weekly Basic medicine
Z by A Corporation Weekly Basic medicine
White Products Ltd. Weekly Basic medicine
ECO Batteries Ltd. In the process of engagement
Basic medicine
JCo. Batteries Ltd. Weekly Basic medicine
Navana Batteries Ltd. Weekly Basic medicine
SunTec Batteries Ltd. Weekly Basic medicine
Gel Tec Batteries Ltd. In the process of engagement Basic medicine
Tamim Batteries Ltd. Part-time Basic medicine
A&P Batteries Ltd. Weekly Basic medicine
Confidence Batteries
Ltd.
Weekly Basic medicine
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6. RECYCLING FACILITY
At present Rahimafrooz, Panna Battery and HAMKO have independent recycling facility
with ISO 14001:2004/2005 and OHSAS 18001:2007 compliant. The list of accreditation
agency, date of issuance of compliance certificate and date of expiration are mentioned
in the Table 7.
Table 7: List of accreditation agency in respect of battery recyclers
Battery supplier
Accreditation agency Accreditation issue date Accreditation validity date
Parent
agency
Subsidiary agency
ISO 14001:2004
OHSAS 18001:2007
ISO 14001:2004
OHSAS 18001:2007
Rahimafrooz IAF
Bureau Veritas 8 Mar 2013 8 Mar 2013 7 Mar 2016 7 Mar 2016
Panna Battery Ltd
AJA 5 Jan 2013 6 July 2013 7 Jan 2016 6 Jul 2014
HAMKO Battery Ltd.
ANAB SAI Global 18 Jan 2012 18 Sep 2012 15 Jan 2015
2 Aug 2015
HAMKO has two rotary furnaces of which one is with capacity of 5 ton and the other one is 8
ton. There are 2 kettles with capacity of 10 ton lead. The monthly capacity is 500 ton, with an
assumption car battery 70% and 30% is inverter, solar and others. Batteries are coming without
acid, breaking is manually done outdoors and under roof.
In Rahimafrooz, there are one rotary furnace with capacity of 10 ton and two kettles with 10 ton
capacity. The monthly capacity is 250 ton lead per month.
In Panna Battery, there are two rotary
furnaces with capacity of 8 ton and two
kettles with capacity of 10 ton. The monthly
capacity is 500 ton lead per month, 20 ton
lead per day and 5 days per week.
Breaking of batteries is done without roof,
very dusty working condition.
For recycling, the other suppliers have
made formal agreement with these three
recyclers, which conforms that the
recyclers will recycle the expired batteries
as are submitted by these suppliers.
In case of EHS compliance, there was requirement to significantly improve the recycling plant of
Panna. Accordingly, they have been found to adopt required mitigation measures as are shown
in Appendix-C (Annex-4).
Figure 03: Basic recycling process
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The Plastic casing of expired batteries are broken manually by using hammer. Thereafter, the
remaining electrolyte is pour in a tank having water to neutralize the acid. After that, the
neutralize acid is let out through a drain to the nearby tertiary collector like canal. The lead bar is
then taken to the recycling plant for melting and casing is crushed to for plastic chips as are
required for manufacturing a new battery casing. The expired battery breaking process is shown
as follows through Photographs 01-04.
Photograph 01: Separation of cover by
manually Photograph 02: Pouring the electrolyte to
neutralization tank
Photograph 03: A view of neutralization tank Photograph 04: Separation of lead bar and
separator
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7. EFFLUENT TREATMENT PLANT
All manufacturing plants have effluent treatment plant (ETP) facility. But there is difference
among technology, efficiency and effectiveness. In this regard, there could be an environmental
audit to assess these ETP and formulate required improvement initiatives. The arrangement of
ETP in terms of capacity and sludge disposal arrangement is shown in Table 08.
Table 08: Arrangement of ETP
Battery supplier Capacity in m3/day Sludge management
option
Rahimafrooz Ac. Ltd. 40 Use as landfill
Panna Batteries Ltd. 10 Do
HAMKO Batteries Ltd. 40 Do
Electro Battery Co. Ltd. 20 Do
Rimso Battery 5.0 Do
Euro Battery 2 Do
Z by A Corporation 0.5 Do
White Products Ltd. 24 Do
ECO Batteries Ltd. 5.0 Do
JCo. Batteries Ltd. 15 Do
Navana Batteries Ltd. 3.5 Do
SunTec Batteries Ltd. 8.0 Do
Gel Tec Batteries Ltd. 2.0 Do
Tamim Batteries Ltd. 10 Do
A&P Batteries Ltd. 2.0 Do
Confidence Batteries Ltd 30
DO
8. AIR TREATMENT PLANT
All battery supplies and expired battery recyclers of IDCOL SHS have made available of air
treatment facility. But there is difference of technology and effectiveness. So, there is necessity
of providing training support on this aspect.
9. STATUS OF BASIC EMS AND OHS COMPLIANCE
Table 9: Compliance of basic EMS and OHS aspects
NIP=Need improvement (1), MS=Moderately satisfactory (2), S=Satisfactory (3)
The status of EMS and OHS compliances by manufacturers and recyclers in respect of some
basic parameters are shown in the abovementioned Table 9, where NIP, MS and S stand for
Need Improvement, Moderately Satisfactory and Satisfactory respectively with a sample value
1, 2 and 3 respectively. Based on the Table 9, it can be said that Euro Battery, Z by A, Gel Tec
and Tamim Batteries Ltd. need significant effort to reach the level of satisfaction.
Battery suppliers and
recyclers
Application of PPE
Status of housekeeping
Training on EMS
and OHS
Availability of trained
professional
Status of documentation
Operation of ETP
and ATP
Arrangement of fire
fighting
Score
Rahimafrooz Accumulators Ltd.
S S S S S S S 21
Panna Battery Ltd.
S MS S S S MS S 19
HAMKO Battery Ltd.
MS S MS MS S S S 16
Electro Battery Co. Ltd.
MS S S MS S S S 19
Rimso Battery Ltd.
NIP MS S MS S MS MS 15
Euro Battery NIP MS MS NIP S MS MS 13
Z by A Corporation
MS MS MS NIP NIP MS MS 12
White Products Ltd.
MS MS MS MS S S S 17
ECO Batteries Ltd.
MS MS NIP MS MS S S 15
JCo.
Batteries Ltd.
MS MS MS S S MS MS 16
Navana
Batteries Ltd.
S MS S S MS MS MS 17
SunTec
Batteries Ltd.
S MS S MS S MS S 18
Gel Tec
Batteries Ltd.
MS MS NIP NIP MS MS MS 12
Tamim
Batteries Ltd.
MS MS NIP MS MS S MS 14
A&P
Batteries Ltd.
MS S MS MS S S S 15
Confidence
Batteries Ltd.
S S S MS S S S 19
15
10. RECOMMENDATIONS AND CONCLUSIONS
In general, the response of battery manufacturers and recyclers on EMS and OHS have been
observed as significantly positive. They have installed ETP, ATP and tried to ensure PPE
properly. But it assumes that in general there is inadequacy of trained professional on EHS in
Bangladesh. So, to reach a complete level of satisfaction, the relevant stakeholders are
requested to think over the following aspects because Figures 01-04, give clear message
about the adverse impact of improper management of lead:
To audit the capacity and effectiveness of ETP and ATP
To train about proper application of PPE
To aware about safe disposal of ETP sludge
To orient them with EHS management practice of developed countries
To monitor the lead content in blood of the workers working in the higher lead exposed area.
Figure 04: Impact of long term exposure to lead Figure 05: Early symptoms of lead
poisoning
Figure 06: Impact of lead poisoning to women Figure 07: Impact of lead poisoning to
children
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Appendix-A
Requirements of ISO 14001:2004 and OHSAS 18001:2007
17
Annex-1: Major requirements of ISO 14001 and OHSAS 18001
Clause no.
Requirement Major issues in brief
4.1 General Requirements This clause requires to clarify whether the EMS system of client is properly adopted, maintained and updated?
4.2 Environmental Policy This clause requires to clarify whether the EMS system of client is communicated with well structured EMS Policy as is to be adopted and authorized by the top management of client?
4.3 Planning This clause requires to clarify whether the EMS system of client is based on a systematic planning like written procedures, hierarchy of risk management measures, process to disseminate information and regulations and so on ?
4.4 Implementation and Operation
This clause requires to clarify whether the EMS system of has made adequate arrangement to ensure proper implementation and operation through deployment of adequate number of competent personnel, regular capacity building arrangement, emergency preparedness measures and so on ?
4.5 Checking and Corrective Action
This clause requires to clarify whether the EMS system of has made adequate arrangement for continual improvement through proper regular checking and adopting corrective actions? In this regard, it is expected that there will be arrangement of performance measurement and monitoring mechanism; accidents, incidents, noncompliance and corrective and preventive actions review procedure; arrangement of keeping records and above all internal audits.
4.6 EMS Management Review
This clause requires to clarify whether the EMS system of has made adequate arrangement of keeping regular communication with the top management through regular management review meeting and keeping minutes of the meeting.
NB. The above table provides requirement of ISO 14001: 2004. However, the requirements of OHSAS are almost same but in case of environmental management system it deals with occupational health safety issues.
18
Appendix-B
EHS Compliance of Battery Manufacturing Plants as have
been enlisted after July, 2012
19
Annex 1- EHS Compliance of Tamim Batteries Ltd.
Photograph : Checking the first aid facility Photograph : Monitoring the operation of ETP
Photograph : A view of ETP Photograph : Aview of fume exhaust arrangement
20
Annex 2- EHS Compliance of A&P Batteries Ltd.
Photographs : Different views of ATP system
Photograph: Application of PPE Photograph : A view of emergency exit plan
21
Annex 3- EHS Compliance of ECO Batteries Ltd.
Photographs: Different views of ATP system
Photographs: Different views of ETP system
22
Photograph: External fire fighting arrangement
Photograph: Internal fire fighting arrangement
23
Annex 3- EHS Compliance of Confidence Batteries Ltd.
Photographs: Different views of ETP system
24
Photographs: Different views of ATP system
A-S Type Foam Type CO2 Type
Photographs: Fire fighting arrangement
25
Photograph: Evacuation Plan during disaster
Photograph: Application of signage
26
Photograph: Disclosure of compliance standard
Photographs: General washing and prayer facility
27
Appendix-C
EHS Compliance of Panna Recycling Plant
28
Annex 4- EHS Compliance of Panna Battery Recycling Plant
Photographs: Different views of Panna Recycling Pant