plastic recycling and reuse in refugee camps · 2019-11-17 · plastic waste in a more productive...
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Plastic recycling and reuse in refugee camps RECYCLING OF PLASTIC WASTE IN MELKADIDA AND JIJIGA REFUGEE CAMPS, ETHIOPIA
Project NO. 2018002-R REV.NO. 0 / 0
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Project
Project title: Plastic recycling and reuse in refugee camps
Document title: Recycling of plastic waste in Melkadida and Jijiga refugee camps, Ethiopia
Document no.: 2018002-R
Date: 2018-08-20
Revision no. /rev. date: 0 / 0
Client
Client: UNHCR
Client contact person: Andrea Dekort
Contract reference: Agreement with EWB Norway
Project Team
Team members: Cathrine Eckbo, EWB Norway
Sten Paltiel, EWB Norway
Anna Østby, EWB Norway
Demissew Eshete, UNHCR Melkadida
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Executive summary
UNHCR is aware of the potential environmental impact of refugees and is increasingly
investigating opportunities to minimize the environmental impacts and maximize
sustainability in refugee operations. UNHCR’s traditional solid waste management
approaches have been focused primarily on avoiding the accumulation of garbage to
prevent vector borne diseases. However, UNHCR now seeks to address the issue of
plastic waste in a more productive manner centered on the promotion of income
generation activities, which target recycling and reuse of plastic waste.
The overall objective of the project is to contribute to the UNHCR objectives of Natural
resources and shared environment better protected and self-reliance and livelihood
program in recycling plastic waste. Consequently, the project intends to implement
plastic recycling business through the provision of recycling infrastructures, establishing
production cooperatives and skill development for both refugee and host community.
The finished recycled product encompasses plastic building materials, furniture,
household equipment and protracted plastic bags or cocoons for raising seedlings in a
clear commercial business model. Another alternative is to produce plastic shredded
material for recycling industries in Addis Ababa. This concept note gives an overview
of technical and economic aspects involved in these activities; it is intended primarily
for entrepreneurs thinking of setting up their own plastic recycling business and for
organisations dealing with communities in refugee and host communities of low-income
areas and who seek opportunities either to create or to increase employment.
A plastic waste generation assessment has been conducted an concluded that the main
types of plastic available in the Melkadida and Jijiga area is plastic water bottles (PET),
plastic jerry cans from cooking oil and water (HDPE) and plastic bags (LDPE). There is
sufficient generation of waste materials to sustain production of plastic produce in the
proposed recycling businesses. Three different business cases has been proposed in this
report; 1) Melt and mould, large scale collecting, shredding, melting and producing
products being sold locally, 2) Small scale production, collecting and producing simple
products that don't need any complex machinery and 3) Shred and sell, collecting,
shredding and selling the shredded plastic to recycling companies in Addis Ababa. The
recommended business model that will give the highest return when economic,
environmental and community benefits are assessed is business case 1) Melt and
mould.
The business implementation strategy will be a two year startup phase with an
implementing partner (NGO) and smooth handing over the business to plastic recycling
community cooperatives. Proposed infrastructure setup for the different areas are:
Melkadida:
Two plastic waste collection and production business cooperatives will be set-
up at Melkadida and Dollo equipped with all required recycling machines and
production facilities
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Small scale plastic waste collection and supplying cooperatives in each camp of
the other four refugee camps (Buramino, Hilwayen, Kobe & Bokolmayo).
Two trucks that collects shredded plastic material from the camps and host
communities to central production centres
Jijiga:
Two plastic waste collection and production business cooperatives will be set-
up at Sheder and Kebribeyah equipped with all required recycling machines
and production facilities
The plant to be set-up in Sheder will also serve for Awbare refugee camp &
host communities.
There is a need for environmental sound solutions as environmental considerations gain
ground legislation changes all around the world. Sustainable development is at the top
of all agendas in the UN, EU and national governments. Better solutions for the rapidly
growing amounts of plastic waste are in demand. High prices of virgin materials will
also make recycling attractive.
Recycling plastics has many benefits, it contributes to energy savings and the reduction
of greenhouse gas emissions. It also saves non-renewable sources like oil and gas. In
addition to that, recycling provides livelihood for millions of people and families in
developing countries, either in the form of formal employment or informal economic
activities. It is therefore recommended to start plastic recycling activities in the refugee
areas.
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What is plastic? - Different plastic types.
The information in this chapter has been obtained from the precious plastic manual on
plastic recycling.
Plastics are synthetic chemicals extracted mainly from petroleum and made of
hydrocarbons (chains of hydrogen and carbon atoms). Most plastics are polymers, long
molecules made up of many repetitions of a basic molecule called a monomer. This
structure makes plastic particularly durable and long lasting. Plastic is causing serious
environmental concerns regarding its slow decomposition rate (recent studies say 500
years) due to its strong bonding molecules.
Thermoset and thermoplastics
There are two main categories in the world of plastics: thermoplastics and thermosetting.
Thermoplastics are the plastics that can be recycled. Thermoplastics can be melted back
into liquid and moulded multiple times. Thankfully, thermoplastics make up to 90% of
global production. Thermosets can melt and take shape only once; after they have
solidified, they stay solid forever. In the thermosetting process, a chemical reaction
occurs that is irreversible.
Plastic types
Thermoplastics are further grouped in seven different subcategories often referred to as
plastic types. Each plastic type has its specific chemical composition, properties and
applications and is given a specific number, called SPI code to differentiate between
them. Today, most manufacturers should follow this coding system and place the SPI
code on their products, usually moulded at the bottom of the product.
Knowing what plastic type you’re working with is crucial when working with plastic
recycling. The different plastic types are:
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1. PET (polyethylene terephthalate)
This is a very strong plastic that can be easily recognised for its transparent look. All
beverage bottles containing sodas are PET. This plastic is also used in many other
products like jars, combs, bags, tote bags, carpets and ropes. Items made from this plastic
are commonly recycled. Most recently, PET is often recycled into yarns to make clothes.
2. HDPE (high-density polyethylene)
This plastic is often used for food or drink containers. Items made from this plastic
include containers for milk, motor oil, shampoos, soap bottles, detergents, and bleaches.
Many toys are also made from this plastic.
3. PVC (polyvinyl chloride)
This is toxic and we do not work with it. PVC is most commonly found in plumbing
pipes and releases chloride when heated up. Do not use with when recycling plastics.
4. LDPE (low-density polyethylene)
Plastic wrap, sandwich bags, squeezable bottles, and plastic grocery bags all are made
from LDPE. Usually, LDPE is not recycled from the industry but works rather good with
the recycling recommended in this report
5. PP (polypropylene)
This is one of the most commonly available plastic on the market. This type of plastic is
strong and can usually withstand higher temperatures. Among many other application,
it is consistently used for products that get in contact with food and drink (Tupperware,
yoghurt boxes, syrup bottles etc.).
6. PS (polystyrene)
PS is most commonly known as Styrofoam. PS can be recycled, but not efficiently;
recycling it takes a lot of energy, which means that few places accept it. Disposable
coffee cups, plastic food boxes, plastic cutlery and packing foam are made from PS.
7. Other mix
This code is used to identify other types of plastic that are not defined by the other six
codes. ABS, Acrylic or Polycarbonate are included in this category and can me more
difficult to recycle.
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Contents
Terms of reference and methodology 10 The assignment 10 Terms of Reference 10 Assignment methodology 11
Project introduction 11 Area description 12
Refugees Settlements and Their Impacts 13 Project background 13 Problem analysis 14 Plastic waste stream assessment 15
Objective 15 Methodology 15 Current plastic waste management 15 Plastic waste generation 19 Summary 20
Assessment of relevant recycled plastic products for production 21 Objective 21 Methodology 21 Demand assessment 21 Calculation of plastic waste needed 24 Summary 27
Plastic recycling technology assessment 28 Objective 28 Methodology 28 Existing plastic recycling machines on the market 28 Existing machines in the project area 28 Energy demand of plastic recycling machines 30
Technical design and equipment 30 Objective 30 Methodology 30 Desirable machines and solutions for the plastic recycling business 31 Energy demand 37 Energy acquisition – cost estimates 39 Summary 41
Business cooperative strategy 42 Melkadida 42 Jijiga 43
Ownership and sustainability 43 Financial and commercial analysis 44
Melkadida 44 Jijiga 46
Viability analysis 48 Melkadida 48 Jijiga 49 Implementation strategy 49
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Environmental and social impact 50 Conclusions 52
Table
Table 1: Plastic waste generation 19 Table 2: Plastic waste generation summary Melkadida 20 Table 3: Plastic waste generation summary Jijiga 21 Table 4: Demand assessment 21 Table 5: Amount of plastic needed for production estimate 24 Table 6: Summary of plastic needed for production 27 Table 7: estimated prices, capacity and energy use of the shredder for the collecting points 33 Table 8: estimated prices, capacity and energy use of the washer for the collecting points 34 Table 9: estimated prices, capacity and energy use of the oven for the collecting points 35 Table 10: estimated prices, capacity and energy use of the extruder for the collecting points 36 Table 11: Estimated energy need 37 Table 12: Estimated capacity need 38 Table 13: Cost calculations Jijiga 40 Table 14: Investment costs Melkadida 41 Table 15: Investment costs Jijiga 41 Table 16: Activities needed in Melkadida 42 Table 17: Activities needed in Jijiga 43 Table 18: Business models for Melkadida 45 Table 19: Business models for Jijiga 47 Table 20: Viability analysis Melkadida 48 Table 21: Viability analysis Jijiga 49 Table 22: possible negative impacts and mitigation measures 52
Figure
Figure 1: Pictures of plastic waste Melkadida 16 Figure 2: Pictures of plastic waste Melkadida 17 Figure 3: Pictures of plastic waste Jijiga 18 Figure 4: Pictures from the demand assessment 24 Figure 5: PET shredding factory in Addis Ababa 29 Figure 6: Plastic waste shredder 29 Figure 7: Plastic shredder 32 Figure 8: Moulding machine (left) and extruder (right) 34 Figure 9: Metal working equipment found on NRC training centre in Melkadida 36
Appendix
Appendix A Activity plan Appendix B Business plan Melkadida
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Appendix C Business plan Jijiga Appendix D Bill of quantity Appendix E Factory and collection point set up
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Terms of reference and methodology
The assignment
This report has been prepared by Cathrine Eckbo, Sten Paltiel and Anna Østby from
Engineers Without Borders Norway and Environment Officer Demissew Eshete from
UNHCR Melkadida sub-office. A plastic waste and reuse opportunity assessment has
been conducted in Melkadida and Jijiga refugee camps and host community in Ethiopia.
The Engineers has been brought in by UNHCR to do this assessment.
The objective of this mission as per Terms of Reference is to carry out in-depth
assessments of the existing plastic waste generation trend in the refugee camps and host
communities and provide clear recommendations for a well-functioning program where
waste is recycled or reused all while generating income for the refugee and host
population.
Terms of Reference
The Terms of Reference of the assignment are as follows:
Both parties agree that the Engineers will contribute with the technical
engineering expertise for an in-depth assessment, planning and advice with
regards to the plastic waste situation in refugee camps in Ethiopia. They will
collaborate closely with UNHCR, the local government and the refugees
themselves in this process.
The Engineers will aid in developing an overall project plan by organizing
workshops and focus group discussions with UNHCR employees, refugees and
local government and in conducting a mapping of existing plastic waste solutions
and related technology currently available.
The Engineers will provide with technical engineering expertise to provide a
mapping of available technology in UNHCR Somali situation refugee operation
areas, Ethiopia. They will provide expert advice and propose the appropriate
technological solutions in order to develop a system for recycling and reuse of
plastic waste which also should be an income generating activity for the refugees.
The Engineers will contribute to the project development addressing each step
of the project cycle for income generating activities (IGA project) and conduct
an analysis of the required resources and external services for product
development and technology (Value chain analysis).
The Engineers will contribute to and provide advice on possibilities of funding
from the private sector and possible investments needed to develop small scale
business for recycling and reuse of plastic waste in the refugee camps.
The engineers will develop a finalized project proposal document for UNHCR
Somali situation refugee operation areas, Ethiopia which includes all parts of the
project cycle including a Results Framework for measuring the expected results.
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All the analysis conducted shall be included in a separate report with clear
recommendations for teams that will provide similar analysis in other countries
where UNHCR have their refugee operations.
Assignment methodology
The assignment was conducted by the engineers together with the Environmental Officer
in Melkadida sub-office. Methodology of the assignment was as follows:
Desktop review and remote consultations with UNHCR country operations to
identify potential Somali refugee operations and host communities that have a
context conducive for plastic waste to value, named as “Trash in to Cash” trials.
Field visit to Melkadida and Jijiga refugee camps and host communities to
survey and quantify the total plastic waste generation. It encompasses visit to
local plastic waste recycling factories in Addis Ababa and stakeholders’
consultation at all levels.
Value chain mapping in each of the identified trial refugee camps and host
communities: to identify existing business operations and functions around
plastic waste products, chain operators and their linkages, as well as the chain
supporters within the value chain.
Technology mapping and infrastructure need assessment: based on the finding
of the value chain analysis, researching on the best technological solutions to
move to a plastic waste recycle and recovery system, based on a social business
model in the refugee camps and host communities.
Labour analysis of waste value chains in each of the target refugee operation
areas: to assess selected technology value chains products and link performance
in terms of economic efficiency and livelihoods development potential.
Impact investment needs: hinging on the results of the value chains and
technology mapping exercise, the mission together with ground project focal
person will analyze on the needs and opportunities for impact investment to
begin waste to value operations. This includes an analysis of opportunities for
private sector investment to begin or upscale micro-enterprises and community
cooperatives based on plastic waste.
Project introduction
With more than 928,663 registered refugees, Ethiopia remains the largest refugee
hosting country on the African continent. The Government of Ethiopia continues to
provide access to asylum, and UNHCR and other humanitarian agencies are allowed to
implement mandate related activities. The government of Ethiopia however maintains
its reservations to the 1951 Convention regarding the right to work and freedom of
movement, relaxed recently in its statement to the 20th September 2016 Obama Leaders
Summit on Refugees, in which the Ethiopian Government indicated its willingness to
provide significant employment opportunities to refugees, through for example, the
development of 100,000 ha irrigation agriculture. Ethiopia adopted its “Refugee
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Proclamation” in 2004, and it is the main national legislation governing refugee issues.
Refugees continue to arrive mostly from South Sudan, Sudan, Eritrea, Somalia and
Yemen. Most refugees are granted refugee status prima facie. The majority of the
refugees are accommodated in camps, while only a smaller percentage of the refugee
population is permitted to reside in urban areas.
Socio-economically, Ethiopia has been severely impacted by the effects of the El Nino
meteorological phenomenon and experienced one of the worst droughts in decades in
2015/2016. It is estimated that some 83% of refugees are located in drought-affected
areas, with approximately 50% of persons of concern hosted in the most critically
affected areas. While rains resumed in early 2016, the loss of livestock and production
assets will continue to have an impact on the country. The general security situation is
considered stable; and although violent protests in parts of the country affect road travel,
areas hosting refugees are generally not directly impacted.
Presently, Somali refugees from Central and Southern Somali are recognized prima
facie in Ethiopia, while Somalis coming from other regions undergo RSD procedures.
Somalis represent the second largest group of refugees in Ethiopia, living across refugee
camps in Jijiga (Sheder, Awbarre and Kebrebeyah) and Dollo Ado (Buramino, Kobe,
Hilaweyn, Melkadida and Bokolmanyo), and to a smaller extent, in Addis Ababa.
As of 31st July 2018, about 218,9291 refugees are living in five camps in Melkadida and
36,916 refugees are living in the three camps in Jijiga.
Area description
Dollo Ado is one of the four Woredas in Liben Zone of Somali Regional State in Ethiopia5. It is located South East of Ethiopia bordering Kenya in the South and Somalia in the South East. It extends from 3.966619o to 4.822247o North and 40.775571o to 42.065945o East with a total land area of about 9,444 square kilometre. The longest width of the Woreda is 157 km in the direction of South East-West while the North-South distance is about 96 km. The average elevation of Dollo Ado is 254 masl even though the altitude varies from 200 m to 1,000 m. The land is generally plain with an average slope of less than 2%. The agro-climate is categorized to low land, Desert, with a mean annual rainfall of less than 200 mm.
1 UNHCR July 2018, population statistics
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Without including refugees, the current population of Dollo Ado (including Boklomayo), based on the CSA population forecast for 2016, is 141,698. The urban population accounts for about 35% of the total. However, according to Dollo Ado Woreda Administration, the population, including Dollo Ado and Boklomayo, is estimated at173,000. Jijiga is the capital of the Somali region of Ethiopia and has a population of 125,876. According to the major, this number is much higher. The climate of Jijiga is a subtropical highland climate. In total, there are 20 urban and 10 rural Kebels in Jijiga.
Refugees Settlements and Their Impacts
Following a couple of decades of civil unrest in Somalia, hundreds of thousands of Somalians sought refuge in Ethiopia. This situation created a load which is beyond the carrying capacity of the desert ecosystem which was already under stress due to increasing population of the host community. This has had an impact on the environment particularly on the biomass resource base due to over dependence for supply of cooking fuel. Firewood has now become a scarce resource over which the host communities and refugees get into conflict. The Federal Democratic Republic of Ethiopia took the initiative of including protection
of public health and Environmental pollution in the 1995 National Constitution.
According to both the Constitution Article 90 and the Environmental protection Policy
provide strong legislative and policy underpinning to “developing safe disposal of
human, household, agricultural and industrial wastes and encouragement of recycling”.
Besides, safe solid disposal and recycling initiative is well aligned to the UNHCR global
strategic priority, UN sustainable development goal and CRRF.
Project background
UNHCR SOMEL is located close to the borders with Somalia and Kenya, in the Somali
region of Ethiopia. Currently, together with the government counterpart ARRA, the
office looks after 214,080 Somali refugees in five refugee camps, established all along
the Dollo Ado-Negelle road within 90 km radius. For new arrivals, a reception centre is
established in Dollo Ado, approximately two kilometres from the Somali border. In
addition to the regular refugee programme, UNHCR SOMEL has also been engaged
with host communities through local woredas, with the aim to foster peaceful
coexistence. Boklomayo is the first refugee camp established in February 2009 in Dollo
Ado Woreda. As the influx of refugees increased over time, the other four camps,
Melkadida, Kobe, Hilaweyn and Buramino were consequently established until the end
of 2011. Of the five SOMEL refugee camps, two of them, Buramino and Hilaweyn, are
located in Dollo Ado Woreda hosted by three kebeles - Buramino, Aminow and
Hilaweyn each with a population of 4,500, 4,300 and 4,700 respectively. The other three
camps: Kobe, Melkadida and Boklomayo are found in Boklomayo Woreda hosted by
five Kebeles namely: Sub-leli, Boklomayo, Melkadida, Kobe, and Hawal Haji. The
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proportion of refugees to host communities in the Kebeles affected is six to one. The
average population density in Genale-Dawa riverine livelihood zone is about 170
persons per square kilometres of which 64 % are refugees.
UNHCR Sub- Office Jijiga (SOJ) was established in 1998 with main objective of
supporting 600,000 refugees from Somalia whom were displaced due to ethnic based
conflict after the fall of the Siad Barre regime. Jijiga is located in eastern Ethiopia, 630
kilometres away from Addis Ababa. Together with the government counterpart ARRA,
the office assists 37,188 individuals in three camps, namely Kebribeyah, Awbarre, and
Sheder.
The disposal of plastics products at both the refugee operations, Melkadida and Jijiga
contributes significantly to environmental impact. Most plastics are not biodegradable
and can persist in the environment for many years. The generated plastic wastes are
blocking the drainage systems and resulting in water logging, flooding and spread of
waterborne diseases. With more and more plastics products, being disposed of soon after
their purchase, the landfill space and animal grazing area required by plastics waste is a
growing concern and has resulted in the death of unconfirmed number of animals over
the last few decades.
UNHCR’s operation in Melkadida and Jijiga are intending to implement “Trash into
Cash” initiative that augment the ongoing refugees’ self-reliance in order to decrease
dependency on humanitarian aid. The upcoming key activities of this initiative be
planned and implemented in line with the national “Growth and Transformation”
development plan, and ensure sustainability of the investment, as well as serving to
address both economic and ecological demands for the refugees and the host community.
Problem analysis
Generally solid waste is becoming a bigger problem in the refugee areas each year.
Households are producing more waste, so disposal sites are filling up and new sites are
further away from residential areas. All the solid wastes except plastic waste are
collected and transported to Addis Ababa for wholesale. There is no nearby recycling
facility around the refugee operation area and the householders have to dispose of plastic
waste themselves selling in low price for moving to Addis. Introduction of plastic
recycling facilities will increase the amount of revenue that they obtain in selling raw
plastic waste that has to be disposed of helps to reduce these problems.
Nowadays, there is a rapid growth in plastics consumption in both Melkadida and Jijiga
operation areas, particularly due to the increasing demand for plastic bottles from
potable water suppliers, oil Jerri cans, it is promising to recycle business. Though the
plastics waste generation in each specific area needs detail assessment, there is a much
wider scope for recycling in these areas due to several factors:
Available labour by both the refugees and host communities, including
trained youths.
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There is an existing trend of selling the plastic waste to recycling companies
that reuse and recycling, with the associated system of collection, sorting,
cleaning and reuse of ‘plastic waste’ or used materials.
There is often an ‘informal sector’ which is ideally suited to taking on small-
scale recycling activities. Such opportunities to earn a small income are
rarely missed by members of the refugee and host communities
There are fewer laws to control the standards of recycled materials. (This
is not to say that standards can be low – the consumer will always demand
a certain level of quality).
Transportation costs are often lower, with hand or donkey carts often being
used.
Low cost plastic raw materials give an edge in the recycling business.
Innovative use of plastic waste collection from camps and nearby towns
often leads to low entry costs for processing or recycling.
In the proposed areas, both at Melkadida and Jijiga the scope for recycling of plastics
will grow as the amount of plastic being consumed increases. Therefore, collecting,
sorting and recycling plastic waste will become a viable business activity benefiting the
refugee and host communities.
Plastic waste stream assessment
Objective
The objective of the plastic waste stream assessment was to identify current plastic waste
management in the area as well as quantify the plastic waste streams in the refugee
camps and host community. This was an important part of the project as it laid the basis
for the feasibility of plastic recycling businesses in the area.
Methodology
All quantification of plastic waste are estimates and based on visual observation and
information given by the local communities, refugees, water bottle and plastic bag
wholesalers and UNHCR country operations.
Current plastic waste management
In the refugee camps in both Melkadida and Jijiga, it is clear that plastic waste is a real
issue. There are few waste management operations implemented in the two areas and so
the plastic waste is abundant in the streets, in trees, along fences and in people's
backyards. There are a few plastic waste collectors in both operations that mainly collect
plastic jerry cans and some PET water bottles for resale to trucks that go to Addis Ababa.
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In the following we will review the plastic waste management in the five refugee camps
in the Melkadida area, Dollo Ado town, the three refugee camps in the Jijiga area and
Jijiga city.
Melkadida
Solid waste management in Melkadida camps is through organised and unorganised
collection. The International Rescue Committee (IRC) is in charge of the WASH
program in the camps which includes collection of solid waste in the common areas. The
waste is being collected in half barrel receptacles and transported through donkey carts
to a semi-permanent landfill at the periphery of each camp zone. Melkadida camps solid
waste generation rates are generally low and waste types ranges from plastics, tin and
biodegradables (human, animals and little food wastes). The refugees are responsible for
putting their waste in different stationed waste bins or at the established waste dumps.
Despite the organised waste collection there is still a lot of plastic around in the
environment, mainly plastic bags, but also different kinds of plastic wrapping and some
water bottles. The plastic bag issue is mostly due to wind in the area that blows the
plastic bags from bins and waste dumps. This results in the same waste being collected
numerous times.
There are several individuals, both from the refugee and host community that collects
and sell plastic waste to trucks that brings it to Addis Ababa to sell to recycling
companies. The plastic waste is mainly jerry cans because the collecting individuals get
paid per kilogram and the jerry cans weigh more than PET bottles. There are some who
collects PET bottles, but few in relative to the jerry can collectors.
The Norwegian Refugee Council (NRC) has previously been a part of a plastic recycling
project that looked into different alternatives for plastic recycling. In this project
recycled plastic products were produced for a short period. Unfortunately, the project
was never properly started due to unfortunate timing and no one to drive the project
forward.
Figure 1 and Figure 2 shows pictures from the field work in Melkadida.
Figure 1: Pictures of plastic waste Melkadida
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Figure 2: Pictures of plastic waste Melkadida
Jijiga
Jijiga camps and host communities present a more densely populated settlement in the
tune of a small town. Solid waste in these camps are also managed through simple pits
dug in the outskirt of the camps. There are no organized way of collecting and managing
solid wastes except in Jijiga city where it is managed by the government as well as
private businesses. There are huge generations of plastic recyclables in Jijiga city
including the refugee camp Kebribeyah which is about 15km from Jijiga city.
There is a company that is working on setting up a waste management system in the city
that includes recycling of plastic. They have started collecting as well as acquired some
necessary equipment, but need some more funding to fully implement the recycling
business. They estimate that there is a total of 200,000 kg of plastic waste being
generated in Jijiga and surroundings each month. For the sake of not disturbing private
initiatives and creating unnecessary competition, The project will not focus on plastic
waste recycling in Jijiga city. The plastic recycling businesses will mainly be placed in
the refugee camps and will support and coexist with the private waste management
company in Jijiga City.
The waste management in the three refugee camps are managed through the WASH
program which is managed by ARRA and the Lutheran World Federation (LWF). There
are several waste pits in the refugee camps where all solid waste are being disposed of,
but many of them are getting full. Some places they also burn the waste.
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In the refugee camps of Jijiga there are a few traders of plastic waste jerry cans that sell
jerry cans to trucks that takes it to Addis Ababa and sells it to recycling companies. Most
people sell the jerry cans to small trucks that buys the jerry cans from the camps, brings
them to Jijiga City and sell them to trucks that goes to Addis Ababa. There are also some
people who take the plastic jerry cans to Jijiga City themselves by donkey cart.
Figure 3 shows pictures from the field work in Jijiga.
Figure 3: Pictures of plastic waste Jijiga
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Plastic waste generation
Table 1 summarises the quantification of the plastic waste jerry can generation in the
five different refugee camps in the Melkadida area, Dollo Ado town and the three
refugee camps in Jijiga. Note that a full waste audit has not been conducted in the area,
so the quantifications must be considered as estimates.
Table 1: Plastic waste generation
Area
Type of plastic
waste
Generation of
plastic waste
in kg/month Comment
Dollo Ado Plastic jerry
cans 15000 kg
Dollo is the biggest area and has a total of ten
jerry can traders, where one of them is slightly
bigger than the others. The estimate is based on
information from the trades about what amount
they collect and sell each month. The estimate is
conservative.
Bokolomayo
refugee camp,
Melkadida
area
Plastic jerry
cans 3500 kg
Bokolomayo represents a mid size area an has a
total of five jerry can traders in the refugee camp
and host community. The estimate is based on
information from the trades about what amount
they collect and sell each month. The estimate is
conservative.
Melkadida,
Kobe,
Hilaweyn and
Buramino
refugee
camps,
Melkadida
area
Plastic jerry
cans 4000 kg
Melkadida, Kobe, Hilaweyn and Buramino
represents small refugee camps and has few
jerry can traders. It was not possible to get
accurate information from the traders about how
much they collect and sell. The estimate is
therefor based on estimates from the other
camps in relation to size of the camps. The
estimate is conservative.
Kebribaya
refugee camp,
Jijiga
Plastic jerry
cans 3000 kg
Kebribaya refugee camp is the biggest camp in
Jijiga and has a total of six jerry can traders. The
estimate is based on information from the trades
about what amount they collect and sell each
month. The estimate is conservative.
Awbare and
Sheder
refugee camp,
Jijiga
Plastic jerry
cans 4000 kg
Awbare and Sheder refugee camps are smaller
camps in Jijiga and has few jerry can traders. It
was not possible to get accurate information
from the traders about how much they collect
and sell. The estimate is therefor based on
estimates from the other camps in relation to
size of the camps. The estimate is conservative.
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PET bottles and plastic bag waste has been estimated based on information from the
PET bottle and plastic bag wholesalers:
Melkadida:
4,500 kg PET bottle waste per month
500 kg plastic bag waste per month
Jijiga:
3000 kg PET bottle waste per month
500 kg plastic bag waste per month
Summary
Plastic waste amounts in the Melkadida and Jijiga area have been calculated based on
interviews with plastic waste collectors and traders, PET bottle wholesalers and waste
management NGOs. The estimates include plastic jerry cans, PET water bottles, and
plastic bags. The estimates will be higher if other types of plastic waste like soft drink
bottles and plastic wrapping is included.
Melkadida area
Table 2 shows an overview of the plastic waste generation in the Melkadida area. Based
on the available the estimated waste generation is 27,500 kg of plastic waste per month.
Table 2: Plastic waste generation summary Melkadida
Area Dollo Ado Bokolomayo Melkadida, Kobe,
Hilawein, Buramino
Jerry cans (kg) 15,000 3,500 4,000
PET water bottles (kg) 4,500
Plastic bags (kg) 500
Total plastic waste generation (kg) 27,500
Jijiga area
Table 3 shows an overview of the plastic waste generation in the Jijiga area. Based on
the available the estimated waste generation is 10,500 kg of plastic waste per month.
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Table 3: Plastic waste generation summary Jijiga
Area Kebribaya Awbare Sheder
Jerry cans (kg) 3,000 2,000 2,000
PET water bottles (kg) 3,000
Plastic bags (kg) 500
Total plastic waste generation (kg) 10,500
Assessment of relevant recycled plastic products for
production
Objective
The objective of assessing different types of recycled plastic products for production
was to make sure that the products being made are useful and excepted by the
community. It is important to include both refugees and the host community in this
decision to ensure that the products being made are in demand.
Methodology
The assessment was conducted by the engineers together with UNHCR country
representatives. The data collection method included field visits to market areas to
observe different plastic items sold on the market, visits to refugee households to see
what type of plastic products they acquire, interviews with shop keepers and refugees
and focus group discussions with refugee representatives.
Demand assessment
Melkadida
Table 4 outlines the different products that was considered the most appropriate in regard
to market demand.
Table 4: Demand assessment
Products Description
Market potential
Type of plastic
Wall tiles
Today some people use metal sheets for protection on the outside of their house walls. These can be replaced by plastic tiles.
Medium PET, HDPE
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Products Description
Market potential
Type of plastic
Water tanks 25 litre
A problem identified in the camps was lack of water tanks outside of public and household latrines for handwashing. Today the refugees only have small size jerry cans for this. When they are empty they are seldom refill. A bigger water reservoir could improve hand hygiene among the refugees.
Big, UNHCR can be the buyer
HDPE
Plastic furniture; chairs and tables
Use of plastic chairs and tables are very common among the refugees and the host community. Especially plastic chairs is widely used. It is important to find a good design that is easy to make and comfortable to use
Big PET
Roof sheets
Metal sheets are used today as roofing for refugee houses. These metal sheets can be replaced with plastic sheets. It is important to design a good solid uniform product. It is possible to add colour if preferable
Big HDPE
Seedling pots
UNHCR have a plant nursery where they use seedling pots to grow their plants. These pots are bought from Addis Ababa and transported to Melkadida. These can be replaced with locally produced pots. It is desirable to make both pots with a closed bottom for plants and open bottom for seedling growth.
Medium PET, HDPE
Rope Ropes for different use. Medium PET, plastic
bags
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Products Description
Market potential
Type of plastic
Household appliances; wash basins and brooms
In the market place a lot of plastic wash basins are sold. This can be made locally. Due to local culture it is not possible to make appliances from reused plastic that are in contact with food or drinking water.
Big PET, HDPE
Woven Bags and mats
These products are easy to make and does not require much processing. Woven mats to sit on outside or bed mats are also in high demand.
Medium Plastic bags
Figure 4 shows pictures from the field of different plastic products that was assessed.
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Figure 4: Pictures from the demand assessment
Calculation of plastic waste needed
Table 5 gives an estimation of the total amount of plastic needed for the different
products that is proposed in the demand assessment. It is important to note that the
quantifications are estimates and not adapted to final design of the products.
Table 5: Amount of plastic needed for production estimate
Products Product specification Area Raw material calculations
Wall tiles
0.3 x 0.3 m in size. 1-2 cm
in thickness as a start, but
this needs to be tested out.
Melkadida and
Jijiga
One m3 of HDPE equals
approximately 1000 kg of HDPE.
Given the thickness of 1.5 cm per tile
the amount of plastic needed is:
30 cm x 30 cm x 1.5 cm = 1350 cm3
1 m3 = 1000000 cm3
1350 cm3 * 0,001 kg = 1.35 kg/tile
The amount of plastic needed is
approximately 1.35 kg of
HDPE/tile. This equals about seven
5 litre jerry cans. To account for
wastage it is estimated 10 5 litre
jerry cans per wall tile.
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Products Product specification Area Raw material calculations
Water tanks
25 litre
Plastic barrels are made of
HDPE. The barrels can be
reused 25 litre waste plastic
jerry cans that are washed
and modified to a water tank
by installing a tap. Another
possibility is to melt and
mould small jerry cans to a
25 litre water tank. The taps
needs to be made separately.
At this time the project has
not looked into making the
taps locally.
Melkadida
It is most desired to make medium
size water barrels of 25 litres. One 25
litre barrel weighs approximately 1
kg. It is possible to reuse the 25 litre
waste jerry cans as they are, wash
them and modify to a water tank by
installing a tap.
To mould a 25 litre water tank the
estimated need of raw material is:
25 l water tank = 1 kg
5 l jerry can = 0.2 kg
1 kg / 0.2 kg = five 5 litre jerry cans
per 25 litre water tank.
The amount of plastic needed is
approximately 1 kg of
HDPE/water tank. To account for
wastage it is estimated six 5 litre
jerry cans per 25 litre water tank.
Plastic
furniture;
chairs and
tables
A standard plastic chair has
a sitting area approximately
40x40 cm and a total height
of 80 cm. A suggested size
of a table is 100x60+70 (l x
w x h). It is recommended
to look further into the
design of the chair and table
to make sure that the design
fits the criteria of the buyer.
Melkadida and
Jijiga
A standard plastic chair of the given
size weighs approximately 3 kg. To
mould a plastic chair the estimated
need of raw material is:
plastic chair = 3 kg
0.5 litre PET bottle = 0.012 kg
3 kg / 0,012 kg = 250 PET bottles
per chair.
The amount of plastic needed is
approximately 3 kg of PET/chair.
To account for wastage it is
estimated 300 PET bottles per
chair.
A plastic table of the given size
weighs approximately 4 kg. To
mould a plastic table the estimated
need of raw material is:
Plastic table = 4 kg
0.5 litre PET bottle = 0.012 kg
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Products Product specification Area Raw material calculations
4 kg / 0.012 kg = 333 PET bottles
per table.
The amount of plastic needed is
approximately 4 kg of PET/table.
To account for wastage it is
estimated 350 PET bottles per
table.
Roof sheets
Suggested size of the roof
tiles are 0.5 x 1 m, with an
initial thickness of 1-2 cm.
It is recommended to aim
for a final thickness of 0.5
cm, when the technique for
production is incorporated.
It is recommended to try
different designs to fit for
purpose
Melkadida and
Jijiga
One m3 of HDPE equals
approximately 1000 kg of HDPE.
Given the thickness of 1 cm per tile
the amount of plastic needed is:
1 x 1 m x 0.01 m = 0.01 m3
1 m3 HDPE = 1000 kg
0.01 m3 * 1000 kg = 10 kg/plastic
sheet
The amount of plastic needed is
approximately 10 kg of
HDPE/plastic sheet. This equals
about 50 5 litre jerry cans. To
account for wastage it is estimated
35 5 litre jerry cans per roof sheet.
Seedling
and plant
pots
It is desirable to make both
pots with a closed bottom
for plants and open bottom
for seedling growth.
Melkadida
The seedling and plant pots can be
moulded or made from modified
plastic waste cans and PET bottles.
The size of the pots needs to be
specified according to demand by
UNHCR.
Rope
It is possible to make
different types of rope from
PET water bottles and
plastic bags using different
techniques. The methods are
simple and do not require
any machinery
Melkadida and
Jijiga
To make a rope from plastic bags
you need approximately 7
bags/meter of rope.
The length of rope from one PET
water bottle depends on the chosen
thickness of the rope.
Household
appliances;
wash basins
and brooms
Most common was 10 – 15 l
wash basins with a diameter
and height of approximately
30 cm. Brooms can be made
from PET bottles.
Melkadida and
Jijiga
5 1.5 litre PET bottles per broom is
estimated. Amount can vary with
design.
The weight of one plastic wash
basin is approximately 2 kg. This
equals about 10 5 litre jerry cans.
To account for wastage it is
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Products Product specification Area Raw material calculations
estimated 15 5 litre jerry cans per
wash basin.
Woven
Bags and
mats
Different designs of bags
and mats (for the bed and
for outside/inside sitting)
are available. The designs
should be made in
collaboration with the
refugees and host
community.
Melkadida and
Jijiga
Quantification depends on final
design.
Summary
Table 6 shows the following products are recommended for the plastic recycling plants
in Jijiga and Melkadida:
Table 6: Summary of plastic needed for production
Product area Amount in kg/item*
Plastic furniture Melkadida, Jijiga 3,6 kg PET bottles per
chair
4.2 PET bottles per table
Building materials Melkadida, Jijiga 2 kg jerry cans per wall tile
6 kg jerry cans per roof
sheet
Water tanks Melkadida 1.2 kg jerry cans per water
tank
Seedling/plant pots Melkadida To be decided when final
design is chosen
Household appliances Melkadida, Jijiga 0.15 kg PET bottles per
broom
3 kg jerry cans per wash
basin
Rope Melkadida, Jijiga 0.4 kg plastic bags per 10
meter rope
Bags and mats Melkadida, Jijiga To be decided when final
design is chosen *Calculation of kg is based on the following weights: one 0.5 litre PET bottle = 12 grams, one 5 litre jerry can = 200
grams, one plastic bag = 5 grams
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Plastic recycling technology assessment
Objective
The objective of this section is to decide on the best technical solution for the factories.
In addition an evaluation on existing plastic recycling machines has been conducted.
Methodology
The study has been a desktop study of globally existing technology as well as meetings
with key institutions for the project, visits to relevant factories and manufacturing
training centers, and talking refugees and host community residents.
Existing plastic recycling machines on the market
The recycling scheme that will be assessed in this report is mechanical recycling.
Mechanical recycling includes shredding, melting and moulding. Globally, plastic
material recycling has commonly been conducted on a very big scale. For instance, most
plastic in Norway has been sent to Germany to be recycled. Therefore, recycling
machines are often complex. A machine can for example both shred and wash in one
machine, either together or the one operation after the other. This is also applicable for
plastic bags.
There are different ways of collecting plastic materials for recycling. Today both source
segregation, and manual and optical sorting at waste facilities are commonly used. Also
to segregate the different types of plastics, both manual sorting and optical sorting is on
the market. With big and complex machines, plastics can be recycled into clothes, water
barrels, rope etc.
Existing machines in the project area
Addis Ababa
There are some machines related to plastic recycling that you can find locally. There is
an estimated 10 recycling factories in Addis Ababa, which probably use different
machines for their operation. Most of these machines are imported from China, and other
countries. There are machine building companies in Addis Ababa who can make the
machines needed for plastic recycling provided they get detailed information about how
the machine should be built. Some of the machines from one of the PET shredding
factories in Addis Ababa are illustrated in Figure 5.
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Figure 5: PET shredding factory in Addis Ababa
Somali region
According to different sources, there are no recycling factories in the Somali region in
Ethiopia. One of the bottle factories that the team visited had installed a little plastic
shredder some years ago, but they do not use it because of low demand for the shredded
material. Figure 6 shows a picture of the plastic waste shredder.
Figure 6: Plastic waste shredder
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Energy demand of plastic recycling machines
Approximately 1,032 kg of HDPE packaging boxes give 1,000 kg shredded material,
with a total use of 340 kWh electricity. Even though these numbers are specific for that
type of plastic, and also the machine used, it can be used as an estimate for other plastic
types. In general, less dense materials use more energy to be shredded, per kg material.
These numbers will be used later in the evaluation of electricity needed for the whole
recycling process.
Technical design and equipment
Objective
To recommend technical solutions in the plastic recycling factories, this chapter
describes the different machines that are found to fit the production in the camps, and
assesses the need of electricity.
The product demand assessment concluded that three main products should be produced
in Melkadida and Jijiga. The products are floor- and roof-tiles, wash basins and chairs
and tables.
Methodology
A desktop study has been conducted to find different solutions to make the desired
products. For the products to be technically desirable to make, four main criteria have
been chosen and used to decide whether a solution will be feasible for the project or not.
The criteria are:
Durability: The machines used for production should last long, and be easy to
repair when they break.
Easy to handle: The machines should be user friendly and possible to handle
for employees with limited training.
No health risk: The machines should be safe to use.
Produce proper products with quality and good design: The outcome of the
process should be high quality products that creates demand
Bill of materials for the machines are attached in appendix D. Suggestions to setups of
the factories and collection points are attached in appendix E.
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Desirable machines and solutions for the plastic recycling
business
There is an online community called “Precious Plastic”, where one main person has
started to make plastic recycling machines and to spread knowledge about these, and
plastic recycling in general for everyone to learn and be able to do plastic recycling. He
makes instructions and blueprints available for free. For many of the recycling machines,
the specifications from this web-page and download-kit has been used to get estimates
on machine size and price. When building the machines, it is important to first determine
the sizes and amounts of plastic that should be recycled, in order to be able to scale the
machines accordingly to take all the plastic that is required in the camps.
The machines and processes that are found to be necessary and possible are:
Pre-wash, label removing and sorting
Shredding
Washing
Moulding in oven
Moulding with an extruder
The machines that are found to be desirable to build in the factories and collecting points
have been assessed in different chapters, where both the description of the machine, the
scaling, costs and energy demand are assessed. Everything is summarized in the chapters
about energy need, and investment costs. Blueprints to the machines can be found on
the precious plastic website.
Pre-wash, label remover and sorting
When the plastic is brought into the factories and the collection points, some of it will
probably be dirty with soil and maybe some remaining food, oil etc. will stick to it. This
should be washed off before starting the shredding process, so that the shredder
machines last longer. This can be done manually with appropriate safety equipment such
as: 1) water resistant working clothes, 2) washing brushes and 3) gloves. There will
probably be no need for soap in this process. It is assumed that cold or luke warm water
is sufficient.
In the same process, labels and caps should be removed. The bottle caps which are
probable made out of PP, should be taken off, and sorted as an own fraction. The labels
that are made of plastic should be collected and used in a compression moulding, as will
be explained later in this chapter. After this the plastic should be sorted by plastic type
(HDPE, PP, PET, etc.), and maybe also color, to be able to choose the output of the
process better.
During the implementing period, it should be evaluated whether this process can actually
be done manually, as suggested, or if an automatic process is required due to the
amounts. It is assumed that the costs of electricity for this purpose is neglectable.
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Plastic shredder
To break the plastic into small pieces to be able to melt them in moulds to whichever
shape is wanted, they should be taken through a shredder. The shredder can be used for
both PP, PET and HDPE which are planned to be recycled in this process. They should
be shredded separately, or in different shredders to be able to keep the materials sorted.
A shredder (Figure 7), typically has rotating metal blades that crush the plastic between
the metal wall of the machine and the blades, or between more rows of metal blades.
When they have been crushed into small enough pieces for the purpose, the pieces fall
through the mesh in the bottom of the machine. If the plastic piece is not small enough
to fall through this mesh, the rotating blades grabs the piece of plastic one more time
and take it through the process over again. The holes in the mesh are adapted to the
desired size of the plastic shredded material. The smaller the size, the higher the energy
demand, due to several rounds of shredding.
Figure 7: Plastic shredder
To calculate the installed capacity needed in the plants and energy need for the same
machines, estimates from three different sources has been used. These have been
compared, to establish an estimate that is as good as possible. It is assumed a need of 7
kW shredders in Jijiga area and 10.5 kW shredders in Melkadida area. The calculations
of shredder size is attached in appendix E.
It is recommended to scale up the shredding machines from Precious Plastic to 3.5 kW,
and install two machines in each of the locations in Jijiga, and three in the locations in
Melkadida, to get a higher reliability of the plant.
Precious Plastic estimates that a shredder with 2kW installed capacity will cost
approximately 200$, based on second hand materials and not including labour. The
actual price will therefore be higher based on the need for larger machines and for the
need of a new generator. The cost is therefore estimated to be USD $1,000 for a 3.5 kW
shredder. It is recommended to find a good source with specific information regarding
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capacity to shred plastic, or to first install a 3.5 kW machine, and test the capacity, before
deciding on the exact quantity of shredders to install, and to evaluate whether the
shredders should be scaled up or down.
Table 7 shows the estimated prices, capacity and energy use of the shredder for the
collecting points. Estimates are per machine.
Table 7: estimated prices, capacity and energy use of the shredder for the collecting points
Area Installed
capacity (kW)
Energy use (kWh) Estimated price
(USD)
Jijiga 2 x 3.5 320 2000
Melkadida 3 x 3.5 1700 3000
Washer
Washing is more effective when the plastic is shredded in small pieces. The desired
washing machine is not complex (open basin with a propel or screw in it). It is assumed
that such a machine can be developed and build in the machine factory in Addis Ababa.
In choosing detergent it is important to consider HSE regulations. Caustic soda is
recommended, which is effective and can easily be neutralized, before being released
into the environment. The water with caustic soda can be neutralized by going through
a small pool with lime solution. It is recommended to use as little caustic soda as possible
in the process, as it is corrosive at high concentrations. An estimate from the PET
shredding factory in Addis Ababa, was that 4000 L of water and less than 300 kg of
caustic soda, gives 25 tons of washed plastic. They had a 5.5 kW washing machine for
this purpose, and washed 100 tons of plastic each month. Jijiga and Melkadida is
assumed to have 3.3 and 5 tons of plastic waste on each site each month. It is therefore
assumed that the washing machine in the sites can be more than 20 times smaller. In this
analysis a 0.5 kW motor is assumed, and it is assumed that the machine run 50% of the
time in all places.
The water in the washing process should be reused back into the machine if possible.
Appropriate safety equipment is required for the employees working with chemicals.
There is a need for warm water in this process. It is recommended to have a water tank
on the roof to get as much hot water as possible from the sun. For cloudy days, it should
still be an opportunity to warm the water with electricity.
Price of the washer is estimated to be USD $1,000 including a wash basin to neutralize
the water after the washing process.
Table 8 shows the estimated prices, capacity and energy use of the washer for the
collecting points. Estimates are per machine.
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Table 8: estimated prices, capacity and energy use of the washer for the collecting points
Area Installed
capacity (kW)
Energy use (kWh) Estimated price
(USD)
Jijiga 0.5 40 1000
Melkadida 0.5 40 1000
Melting and moulding
There are two ways to melt and mould new products. Both of these processes have been
assessed to give value to the factories that are going to recycle the material. It is
recommended to have two machines, in case one of them needs repair.
It is recommended to use the shredded products with the correct color for the end
product, when deciding which plastic to use in the production. If the desired color is
different from the plastic products coming in, it should be assessed in the implementation
period if paint should be used in the process or the products should be painted afterwards.
For the moulding process, it should be investigated whether a “mould release” is needed,
to get the products out of the moulds when finished. This will probably depend on which
metal is used for the moulds, and the plastic type used. It should be produced more of
the same moulds for each machine, so one can start to produce a new product while the
last product is cooling down inside the mould. Figure 8 shows a picture of a moulding
machine and an extruder.
Figure 8: Moulding machine (left) and extruder (right)
Oven to mould in:
A moulding oven looks much the same as a normal cooking stove, where one turn up
the temperature to a specific degree (it depends on the plastic type used which
temperature it should be), and a mould filled with shredded plastic is put inside the oven.
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While the plastic is melting, the oven presses the mould up against the “roof” of the
oven, so that the plastic inside the mould is pressed out into every corner of the mould.
This works because the top sheet of the mould can move down into the mould, and make
the mould so small that all room is filled up.
For the factories, it is recommended that these ovens are build big enough to mould
0.5x1 m roof sheets. The oven should therefore be a bit more than 1 x 1 m in width and
depth, and at least 0.5 m high, to be able to make other things with different shapes also.
The oven can also be used to make other products, such as water barrel parts, flower
pots, floor tiles, and furniture parts etc.
To be able to melt at least PET, PP and HDPE, which are the main plastic types in the
area, it is assumed that an oven that can heat up to 280 degrees Celsius is needed. It is
assumed that this oven will use approximately 5 kW of power. It is assumed that it will
take no longer than 30 minutes to mould one tile. It is recommended to acquire two
ovens in Melkadida and one oven in Jijiga to be able to process the amount of plastic
waste available.
For energy use calculations it has been assumed that the extruders in Melkadida and
Jijiga run on 90% of their capacity based on amount of waste available and production
amount per month.
Price of the 1 x 1 m compression oven is estimated to be USD $1,000. It is assumed
that a smaller oven will be installed in all collection points. This is assumed to run 50%
of the time.
Table 9 shows the estimated prices, capacity and energy use of the oven for the collecting
points. The energy use is based on 20 working days of 8 hours each month.
Table 9: estimated prices, capacity and energy use of the oven for the collecting points
Area Installed
capacity (kW)
Energy use (kWh) Estimated price
(USD)
Jijiga 1 x 5 720 1 000
Melkadida 3 x 5 2400 3000
All collection points 1 x 4 320 900
Injection moulding with extruder:
Injection moulding is a process where the plastic melts inside the injection machine,
before it gets pushed into a mould. The mould is cold, so that the plastic cools down and
stiffens when pressed into it. The moulds can be shaped as a beam (for furniture
construction), flower pots, floor tile, etc.
For the machine a motor with 70 rpm is needed and it is assumed that this will require a
2 kW installed capacity. To make one beam of one meter would take approximately 10
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minutes. This makes it possible to make a set of legs to either chairs or tables in
approximately 40 minutes. Assuming a weight of 2 kg per beam an estimated amount of
480 kg of plastic can be processed per extruder in one month based on eight hour work
days, 20 days per month. It is recommended to acquire three extruders in Melkadida and
two extruders in Jijiga to be able to process the amount of plastic waste available.
For energy use calculations it has been assumed that the two extruders in Jijiga run on
50% of its capacity based on amount of waste available and production amount per
month. In Melkadida the extruders will run on 100% of their capacity.
Price of the extruder is estimated to be USD $1,100. Table 10 shows the estimated prices,
capacity and energy use of the extruder for the collecting points. The energy use is based
on 20 working days of 8 hours each month.
Table 10: estimated prices, capacity and energy use of the extruder for the collecting points
Area Installed
capacity (kW)
Energy use (kWh) Estimated price
(USD)
Jijiga 2 x 2 330 2 200
Melkadida 3 x 2 960 3 300
Equipment for making moulds:
Many moulds can be made relatively easy with metal working machines, such as
welding machines, metal cutter and a sander. This equipment was found on the NRC
training facility in Melkadida area, as shown in Figure 9.
Figure 9: Metal working equipment found on NRC training centre in Melkadida
It is recommended to use metal for the moulds due to its high heat capacity and to avoid
the plastic sticking to the sides of the mould. It is also recommend to have these small
machines on the main factories, to let the cooperative make their own moulds when they
want to. They should also get training to know how to use these machines. The collecting
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points can ask for moulds to be made at the main factories. It is assumed that the energy
use for this is neglectable.
Blow moulding:
To make water barrels, it is normal to use a technique called blow moulding. In this
process it is necessary to have a finished product of plastic to put into the blow moulding
machine, before it gets heated up and blown into the correct shape. This can probably
also be produced at site, but the process seems too complicated to be reliable at the
factories in Melkadida and Jijiga.
Another way to make smaller barrels is to make both sides in two different moulds, and
then melt the parts together. This needs to be looked further into.
Energy demand
Amount of energy needed for the machines has been assessed and is summarised in
Table 11. It is assumed 0.5 installed capacity to cover the lighting need and other small
equipment.
Table 11: Estimated energy need
Site Shredder kWh/month
Washer (kWh/month)
Oven (kWh/month)
Extruder (kWh/month)
Lighting
etc. (kWh/month)
SUM
Jijiga area
Sheder
factory
1120 40 720 330 80 2300
Kebribayah
factory
1120 40 720 330 80 2300
Awbare
collecting
point
1120 40 320 - 80 1600
Melkadida area
Melkadida
factory
800 40 2400 960 80 4300
Dollo Ado
factory
800 40 2400 960 80 4300
Bokolomayo
Collecting
point
800 40 320 - 80 1200
Kobe
collection
point
800 40 320 - 80 1200
Hilwayen
collection
point
800 40 320 - 80 1200
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Buramino
collection
point
800 40 320 - 80 1200
The capacity needed for all machines and equipment in all different locations are
summarized in Table 12.
Table 12: Estimated capacity need
Site Shredder kWh/month
Washer (kWh/month)
Oven (kWh/month)
Extruder (kWh/month)
Lighting
etc. (kWh/month)
SUM
Jijiga area
Sheder
factory
2 x 3.5 0.5 1 x 5 2 x 2 0.5 17
Kebribayah
factory
2 x 3.5 0.5 1 x 5 2 x 2 0.5 17
Awbare
collecting
point
2 x 3.5 0.5 1 x 4 - 0.5 12
Melkadida area
Melkadida
factory
3 x 3.5 0.5 2 x 5 3 x 2 0.5 27.5
Dollo Ado
factory
3 x 3.5 0.5 2 x 5 3 x 2 0.5 27.5
Bokolomayo
Collecting
point
3 x 3.5 0.5 1 x 4 - 0.5 15.5
Kobe
collection
point
3 x 3.5 0.5 1 x 4 - 0.5 15.5
Hilwayen
collection
point
3 x 3.5 0.5 1 x 4 - 0.5 15.5
Buramino
collection
point
3 x 3.5 0.5 1 x 4 - 0.5 15.5
Operational time of machines
Shredders – 100 %
Ovens – 90 %
Washer – 50 %
Extruders – 50 % (Jijiga) and 100 % (Melkadida)
It is recommended that enough capacity is installed for all the machines to run at the
same time. It is possible to lower the installed capacity with a couple kW, and still get
everything through the machines.
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An estimated need of capacity of 17 kW is assumed for the factories in Jijiga, and
27.5 kW in Melkadida. In the collecting points 12 kW will be needed in Jijiga, and
15.5 kW will be needed for the collecting points in Melkadida area.
Energy acquisition – cost estimates
When deciding between solar panels and diesel generator, it is important to take
environmental impact into consideration. Using solar power is recommended because it
is environmentally friendly and dependable. A solar technician cooperative established
locally in the Melkdadida area will also create local value. In Jijiga it is also assumed
that someone in the town works with solar panels, and that is will create local value there
as well.
Three cases has been assessed in this report:
1) Only solar panels
2) Solar panels and diesel generators (for when it is cloudy)
3) Only diesel generators
A solution using a battery has not been assessed at this stage, due to the batteries short
life span in harsh environments, and with non-optimal charge and discharge of the
batteries. This way electricity can also be given to the people living in the area, when
there is excess electricity on sunny days. It is also assumed that operation of the plant
will happen during the day.
Solar panels
It is assumed that on cloudy days, the solar panels produces 50% of the installed
capacity. If installing only solar panels as the energy source it is recommended to install
twice as much solar capacity as is needed on a sunny day. A cost of USD $1500 per kW
installed capacity of solar panels is assumed.
To find the required area for the solar panels, a thumb rule that 10 m3 space is needed
for one kW installed capacity. For the biggest factory, in the Melkadida region, 550 m3
land will be needed for installation of panels. In Jijiga the factories will need 340 m3
land for this purpose, and the collecting points need 310 m3 and 240 m3 respectively in
Melkadida area and Jijiga area. Further assessments should be done to find the optimal
dispatch between solar panels, batteries and diesel generator, depending on the available
space for solar panels.
Solar panels and diesel generator
In the case with solar panels and diesel generator, the solar panels are scaled to produce
just enough electricity when the sun is shining, and when it is cloudy diesel generator
will be used. The diesel generator is scaled to be able to take half of the energy
production when it is cloudy. Hence, the installed capacity should be half of the total
capacity need.
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Diesel generator
For the diesel solutions, a cost of USD $ 5 500 is assumed for a 5 kW diesel generator,
and a cost of USD $ 14 500 for a 20 kW diesel generator. The sizes between these two
have been extrapolated linearly. It is also assumed that a litre of diesel costs USD $ 0.8
per litre, and that the generators can produce 3 kWh with 1 L diesel, due to the bad
efficiency it is on electricity production from fuel.
Cost estimates
Table 13 shows the calculations of costs for Jijiga:
Table 13: Cost calculations Jijiga
Jijiga Oversized solar Solar and small
diesel
Diesel generator
installed
capacity/month
34 kW 17 kW solar
+ 8.5 kW diesel
17 kW
Costs/month 51 000 $ 25 500 $ + 7
500 $
+ 460 $
fuel/month
12 500 $ + 1840 $
fuel/month
The solar panel solution will be more profitable than the solar + diesel case when the
fuel costs exceeds USD $ 18,000. With fuel costs of USD $ 460 per month, it will take
3.3 years for the solar panel solution to be more profitable. The solar panels are also
dimensioned to produce twice as much electricity as needed when sunny. For the case
using only a diesel generator it will take 1.7 years for the solar panel solution to be more
profitable.
The results seems to be pointing so strongly in one direction, that it is assumed that the
solar panels will be the cheapest solution for all factories and collection points, and only
calculations for solar panels have been investigated further. It is still recommended to
have a diesel generator at the sites, in case the solar system fails. This is assumed to cost
USD $ 5,500 in addition to the solar panel installation. Cost estimates for solar panel for
the rest of the factories/collection points are:
Melkadida factory:
Installed capacity 55 kW
Costs USD $ 82,500
Melkadida collection point:
Installed capacity 31 kW
Costs USD $ 46,500
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Jijiga collection point:
Installed capacity 24 kW
Costs USD $ 36,000
Investment costs
Total investment costs for Melkadida and Jijiga are estimated in Table 14 and Table 15.
Table 14: Investment costs Melkadida
Bokolo-
mayo
Melkadida Kobe Hilwayen Buramino Dollo
Ado
Power supply 18,000 60,000 18,000 18,000 18,000 60,000
Shredder 3,000 3,000 3,000 3,000 3,000 3,000
Washer 1,000 1,000 1,000 1,000 1,000 1,000
Oven 900 3,000 900 900 900 3,000
Extruder 3,300 3,300
Sum 22,900 70,300 22,900 22,900 22,900 70,300
Table 15: Investment costs Jijiga
Sheder factory Kebribayah
factory
Awbare
collecting point
Power supply 56,500 56,500 41,000
Shredder 2,000 2,000 2,000
Washer 1,000 1,000 1,000
Oven 1,000 1,000 900
Extruder 2,200 2,200
Sum 62,700 62,700 44,900
Summary
It has been found technically feasible to make floor- and roof tiles, furniture and flower
pots out of the plastic material. Before moulding the plastic needs to be shredded and
washed.
All Jijiga cooperatives need two shredders of 3.5 kW, while all Melkadida cooperatives
needs three of the same type. One moulding oven is enough in all receiving points and
the factories in Jijiga, while the factories in Melkadida needs two ovens to be able to
produce products of all the plastic material. Furthermore Jijiga factories needs two
extruders, while Melkadida needs three.
The most cost effective solution, of the options available in the areas, is to build solar
panels which provide enough electricity also when cloudy.
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Business cooperative strategy
The aim of the project is to encourage as many as possible to be part of the value chain
created from the plastic waste. Setting up cooperatives in each camp will be the best
platform to achieve this. Although not discussed in this chapter, it is recommended to
also consider making houses or community buildings from Ecobricks (PET bottled filled
with sand). A business plan for this is attached in appendix B.
Melkadida
The businesses will be organized through separate cooperatives in each refugee camp as
well as Dollo Ado town
Establishing the cooperatives will be done during the first year of the project which is
the implementation phase. After that a one year production trial will commence. One
NGO should have the responsibility for setting up the cooperatives and follow up in the
implementation and production trial period. There should also be allocated funds for a
follow up after this period to be able to do necessary adjustments.
The activities needed will be distributed between the different cooperatives according to
Table 16.
Table 16: Activities needed in Melkadida
Steps
Bokolomayo Melkadida Kobe Hilaweyn Bur-
Amino
Dollo town
Collecting
plastic
waste
Individuals collect and sell
To local project collection stations
Processing
Sorting,
washing,
shredding
and simple
production
Main
processing
plant.
Including
sorting,
washing,
shredding
and
processing.
Also
collection
of
shredded
material
Sorting,
washing,
shredding
and
simple
production
Sorting,
washing,
shredding
and
simple
production
Sorting,
washing,
shredding
and
simple
production
Main
processing
plant.
Including
sorting,
washing,
shredding
and
processing.
Also
collection
of shredded
material
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It is recommended that Melkadida cooperative have an overall responsibility to follow
up and coordinate the total activity at the different cooperatives.
Jijiga
Due to possible conflict of interest with private enterprises in Jijiga town it was decided
not to include Jijiga town in the following business models.
The businesses will be organized at separate cooperatives placed in two of the refugee
camps, Sheder and Kebribayah. The activities needed will be distributed between the
different cooperatives according to Table 17.
Table 17: Activities needed in Jijiga
Steps Kebribeyah Sheder Awbare
Collecting plastic
waste
Individuals can collect and sell to local project collection
stations
Transport to local
processing
plant
Project do the necessary transport
Processing
Two main plants sorting, washing,
shredding, moulding
Sorting and
production of hand
crafts.
Ownership and sustainability
Implementing the cooperative strategy with long term support, will result in a business
that is solid and sustainable for the future. It is important that the employers feel
ownership to the business and in that way will do the extra effort sometimes needed to
keep a business running successfully for many years.
The main guarantor of sustainability is the level of engagement in and ownership of the
project at community level in business model approach.
The plastic waste recycling business will be operational through registered cooperatives
composed of both host and refugee communities. The cooperatives will be registered at
Ethiopia Somali Bureau of cooperatives as a community based business enterprises. The
business is run by and executive committee elected by the members of the community
based business cooperatives.
The business will be operational at a medium scale, collection and sorting of plastic
waste, producing diversified recycled plastic articles and products in a sustainable
business model. The plastic recycling business cooperatives in collaboration with the
local administration appeal to own for the factory land acquisition, for this purpose.
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To run the business, the Cooperatives will appoint a board of directors who will in turn
appoint a managing director. A sales and marketing manager, quality control manager,
personnel manager and a financial accountant are other planned key personnel. The first
year will mainly deal with plastic waste collection, sorting and shredding activities and
in the following years, recycled plastic product diversification will commence.
By promoting increased self-reliance of the refugees and building resilience of the host
communities, UNHCR expects this project will give the refugees and host communities
the opportunity to participate in Environmental protection and livelihoods self-reliance
programmes that will reduce poverty levels, in line with the Ethiopian Government’s
National Development plans, UN sustainability development goal, and CRRF.
Eventually, this will ensure the community empowerment and sustainability of the
investments made in Melkadida and Jijiga.
Financial and commercial analysis
Melkadida
Based on the baseline mapping and previous discussions we see the following viable
business Ideas:
Complex moulding of building materials, furniture, wash basins, water tanks and
plant pots
Producing less complex articles from plastic waste like ropes, brooms, bags and
mats
Collecting, sorting, shredding and washing plastic waste and sell to plastic
recycling company in Addis Ababa
Table 18 outlines the business models along with costs and revenue per site. Complete
business plans are attached in appendix B. All costs and revenue are based on estimated
selling amounts per month, required raw material, selling price, monthly salary and other
costs. All numbers are estimates.
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Table 18: Business models for Melkadida
*There will also be private collectors that will benefit from the business, by selling collected plastic waste to the cooperatives.
**Based on estimated prices and selling amount of selected products
Business Number of employees
Investment costs Monthly costs
Monthly revenue
Number of CBOs involved
Environmental impact
b
Melt and mould the plastic
waste to identified needed
products
15 employees* USD$ 275,200
USD$ 2,444 including: -Labour -Materials -Electricity USD$ 5,000
Two main cooperatives in Melkadida and in Dollo Ado.
-Reuse of plastic waste -Less import of goods
c Produce less complex
articles from plastic waste
15 employees* USD$ 16,100
Must be calculated when deciding on final products and design. USD$ 790**
All of the cooperatives
-Reuse of plastic waste -Less import of goods
d
Collecting, sorting,
shredding and washing and
selling to recycling
companies in Addis Ababa
10 employees* USD$ 106,200
USD$ 14,015 including: -Labour -Materials -Electricity
USD$ 20,453 Assuming sales of all monthly produced plastic
All of the cooperatives
-Plastic waste clean up
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Jijiga
Based on the baseline mapping and previous discussions we see the following viable
business Ideas:
Complex moulding of building materials, furniture and wash basins
Producing less complex articles from plastic waste like ropes, brooms, bags and
mats
Collecting, sorting, shredding and washing plastic waste and sell to plastic
recycling company in Addis Ababa
Table 19 outlines the business models along with costs and revenue per site. Complete
business plans are attached in appendix B. All costs and revenue are based on estimated
selling amounts per month, required raw material, selling price, monthly salary and other
costs. All numbers are estimates.
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Table 19: Business models for Jijiga
Business Number of employees
Investment costs Monthly costs
Monthly revenue
Number of CBOs involved
Environmental impact
b
Melt and mould the plastic
waste to identified needed
products
15 employees USD$ 113,300
USD$ 2,420 including: -Labour -Materials -Electricity USD$ 4,840
Two main cooperatives in Sheder and Kebribeyah
-Reuse of plastic waste -Less import of goods
c Produce less complex
articles from plastic waste
6 employees USD$ 16,400
Must be calculated when deciding on final products and design. USD$ 790** All sites
-Reuse of plastic waste -Less import of goods
d
Collecting, sorting,
shredding and washing and
selling to recycling
companies in Addis Ababa
12 employees USD$ 37,400
USD$ 4,830 including: -Labour -Materials -Electricity
USD$ 6,885 Assuming sales of all monthly produced plastic
Two main cooperatives in Sheder and Kebribeyah
-Plastic waste clean up
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Viability analysis
When selecting a business case it is important is to select a case that’s economically
sustainable after the initial 2 years implementation and production trial period that gives
as much positive back to the refugees and host community as possible. Table 20 and
Table 21 outlines a viability analysis of the two main different activities that has been
proposed in this report.
Melkadida
Table 20: Viability analysis Melkadida
Business Monthly
costs Monthly revenue
Bottom line
Environmental impact
Community impact
a Collect, shred,
melt and
remould
USD$ 2,444 USD$ 5,000
+ USD$ 2,556
Recycling of plastic waste,
environmental clean up, less
burning of plastic waste, less transport
High local benefit, possible
employment of many
refugees and host
community residents,
local produce, skill development
b Collect, shred,
wash and sell
USD$ 14,015
USD$ 20,453
+ USD$ 6,438
Recycling of plastic waste,
environmental clean up, less
burning of plastic waste
Moderat local benefit,
possible employment
of many refugees and
host community residents
* Wage 40$/month/worker (based on 1000Birr/month)
Based on Table 20 Case b is the most economically viable alternative, but gives less to
the local community and has less environmental benefits.
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Jijiga
Table 21: Viability analysis Jijiga
Business Monthly
costs Monthly revenue
Bottom line
Environmental impact
Community impact
a Collect, shred,
melt and
remould
USD$ 2,420 USD$ 4,840
+ USD$ 2,420
Recycling of plastic waste,
environmental clean up, less
burning of plastic waste, less transport
High local benefit, possible
employment of many
refugees and host
community residents,
local produce, skill development
b Collect, shred,
wash and sell USD$ 4,830
USD$ 6,885
+ USD$ 2,055
Recycling of plastic waste,
environmental clean up, less
burning of plastic waste
Moderat local benefit,
possible employment
of many refugees and
host community residents
Based on Table 21 Case a is the most economically viable alternative.
Implementation strategy
The business cases needs to be implemented in different sequences starting with basic
processing like washing/shredding to get the organization and technology in place. It is
recommended to select one site to test the different technologies suggested before
implementation and to choose one technology development partner (to make machines
etc.).
The strategy will adopt the implementation of the initiative relies heavily on community
engagement and youth economic empowerment. Emphasis will be placed on both the
host and the refugee community as the key implementers and co-owners of the
programme in order to ensure the business sustainability. The role of UNHCR and
implementing partners is important for this process in the initial stages, but the goal will
be to try to phase out their direct involvement as systems and processes are put in place
for the communities to take over. The exercises undertaken with communities to assess
strengths are inspiring and motivating as they help people realize that they are not
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helpless, but rather have power in decision-making, which can, in itself, result in
increased active participation. The business operators will be linked to micro-finance
institutions to enlarge the plastic recycling business and the varieties of finished
products.
On the other hand, the Woreda, Zonal and Regional authorities involvement will
be optimised to introduce local guidelines that will sanction the use of non-reusable
plastic sheets for any purpose through the introduction of relevant taxes and
mobilization of the community to minimise the generation of the valueless plastic
waste and replace it with more environmental friendly use such as own shopping
bags, preferably made of cloth or Kaki bags and other recycled material rather than
thinner plastic bags.
Environmental and social impact
The construction and operation of the proposed plastic waste recycling facility will have
both positive and negative impacts as outlined in the preliminary assessment. However,
the study has established that the negative environmental impacts can be ameliorated
through implementation of mitigation measures that are outlined in this report. It is thus,
recommended that the project be allowed to go on provided the mitigation measures
outlined in this report including the Environmental Management Plan (EMP) are fully
implemented and adhered to. It is also recommended that the proponent of the project
fully complies with all statutory and regulatory requirements required of such projects.
Considering the many benefits of the project, it is recommended that the national and
regional Environmental protection authorities will presumably approve and grant the
environmental impact assessment licence for it to continue. The aim of carrying out the
Environmental Impact Assessment is to ensure that development projects do not
negatively affect the environment.
A project of this magnitude is bound to have environmental impacts. These impacts have
been categorized into two: (1) Impacts on the natural environment and (2) impacts on
the human and animal environment. Impacts on the natural environment include those
on land, air and water. The human impacts are largely social and economic in nature.
Further classification of the impacts have been done based on the project life cycle i.e.
impacts during construction, operation and decommissioning stages of the project. The
identified potential negative impacts during construction and operation phases include
change in land use, clearance of vegetation and crops, emissions from construction
vehicle, noise and vibrations, excess soils from excavation, dust generation, risks of
accidents and injuries to workers, habitat alteration, alteration of micro climate,
interference with the river’s ecosystem and erosion of the river bed and banks among
others.
In order to ensure sustainability of the project, several mitigation measures have been
suggested. Suggested mitigation measures during construction phase include sprinkling
of the ground with water to minimize dust, proper servicing and tuning of the machinery
to reduce noise and vibrations; and the provision of construction workers with the
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necessary protective gear to ward off risks of accidents and injuries. Thereafter adequate
landscape management will be undertaken to create balanced environment. There will
be environmentally sound disposal of waste water through ultra-modern septic tank that
will be provided. Solid waste would be disposed of in well-designed dust bins which
will be emptied by the building management from time to time. A system for continuous
monitoring of the project will be in operation throughout its life cycle. The
implementation of the suggested mitigation measures will ensure that the significant
impacts of the project are controlled to a large extent.
Besides, a comprehensive environmental management plan has been prepared to guide
the proponent and contractor in addressing the identified adverse environmental impacts
of the project. Strict adherence to the environmental management plan provided is
recommended to ensure environmental sustainability of the project.
Reuse can be very helpful for disadvantaged people who cannot afford to buy new
goods. These could include clothing, building materials, and business equipment. Reuse
centres that collect and distribute reusable goods can also provide community benefits
by engaging in job-training programmes and general training for the long-term
unemployed, disabled people and young people.
By reusing materials rather than creating new products from raw materials, there are
fewer burdens on the economy as a whole – especially if reuse results in a reduction in
raw material and product imports. Reuse is an economical way for many people to
acquire the items they need. It is almost always less expensive to buy a used item than a
new one.
Reusing something uses little or no water, energy or other resources and is unlikely to
cause pollution. As well as these benefits, reuse eliminates the environmental damage
that would have been caused if the item had been disposed of, rather than reused. In
contrast, manufacturing a product from raw materials (and, to a lesser extent, recycling)
consumes resources, causes pollution and generates wastes
The intention of the project is to improve both social and environmental aspects. This is
done through beating plastic pollution in the project areas, creating jobs for both refugees
and host communities and improving the livelihood of communities. The project
contributes towards the development of local economy and improving ecology.
Possible negative impacts and Mitigation measures are shown in Table 22:
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Table 22: possible negative impacts and mitigation measures
Impacts Mitigations
Interfering in business opportunities in
host communities
Discuss with host community to insure this
don’t happened.
Air pollution from diesel generator Use solar energy where possible
Ground pollution from washing water Implement a cleaning system for washing
water
Tension between host community and
refugees
Insure that also host community also
benefit from project
Tension between people getting work
and others
Try to involve as many as possible in
activities connected to the business
Conclusions
There is a need for environmental sound solutions as environmental considerations gain
ground legislation changes all around the world. Sustainable development is at the top
of all agendas in the UN, EU and national governments. Better solutions for the rapidly
growing amounts of plastic waste are in demand. High prices of virgin materials will
also make recycling attractive.
The project’s objective is to provide support to the refugee and host communities to
recycle plastic wastes in a business model, in order to decrease their dependency on
external aid and to ensure that a significant level of self-reliance is achieved once return
to Somalia becomes possible. This goal will be accomplished by applying best practices
and innovation to livelihoods/self-reliance and education activities, and ensuring
sustainable development to benefit the refugee and host communities. An area of intense
focus in this initiative will be to address sustainable economic and ecological
development needs by exploring plastic waste recycling business. The introduction of
plastic recycling business helps to create more employment opportunity in addition to
its significant merit to protect environmental pollution in and around the Melkadida and
Jijiga Refugee camps.
Recycling plastics has many benefits, it contributes to energy savings and the reduction
of greenhouse gas emissions. It also saves non-renewable sources like oil and gas. In
addition to that, recycling provides livelihood for millions of people and families in
developing countries, either in the form of formal employment or informal economic
activities.
It is recommended in this report to set up plastic recycling businesses in Melkadida and
Jijiga area to collect, recycle and reuse plastic waste, produce local products to be sold
on the local market and create jobs and business opportunities for refugees and host
community alike. The businesses should be led by an NGO in the first two implementing
years, before handed over to the plastic recycling community cooperatives. The final
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number of employees will be decided after the 2 year implementing phase. It is
recommended to use the implementation phase of the project to test which types of
plastic that can be used for different production materials and to be open to look into the
possibilities of other moulds than the ones recommended in this report.
Suggested infrastructure in the two areas are:
Infrastructure set-up for Melkadida:
Two plastic waste collection and production business cooperatives will be set-
up at Melkadida and Dollo equipped with all required recycling machines and
production facilities
Small scale plastic waste collection and supplying cooperatives in each camp of
the other four refugee camps (Buramino, Hilwayen, Kobe & Bokolmayo).
Two trucks that collects shredded plastic material from the camps and host
communities to central production centres
Infrastructure set-up for Jijiga:
Two plastic waste collection and production business cooperatives will be set-
up at Sheder and Kebribeyah equipped with all required recycling machines
and production facilities
The plant to be set-up in Sheder will also serve for Awbare refugee camp &
host communities.
Throughout the implementation period it should be established if the estimated
production amounts assumed in this analysis was correct and if it is necessary to invest
in more machinery.
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Appendix A
ACTIVITY PLAN
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Melkadida and jijiga
Activity Responsible
Select implementation partner NGO UNHCR
Select a technology partner to help design
machines EWB, UNHCR
Select a local firm to produce machines.
This firm will be responsible for training
of staff to operate the machines and
maintenance EWB, UNHCR
Select areas for setup of production plant.
Decide layout and architectural design. EWB, UNHCR
Select key personnel and involve them in
the implementation process UNHCR
Get the shredder and washer in place
early to start training of the basic process.
Get this working at one site and then
implement on the other sites NGO
Implement HSE inspection program for
all production sites NGO, UNHCR
Start the implementation of the collection
process when the basic processes are
ready NGO, EWB
Use the first stages of the project to get a
better overview of the plastic waste
quantities. NGO, EWB
Start implementation of the production
process when the basic processes are in
place. Make sure it works in one place
before expanding. NGO, EWB
After one year do an assessment of
business viability and make necessary
adjustments EWB, UNHCR
Second year production phase NGO
Transfer business to established
cooperatives NGO, UNHCR
After two years do another viability
assessment and make necessary
adjustments EWB, UNHCR
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Appendix B
BUSINESS PLANS MELKADIDA
Contents
Melt and mould 57 Product 57 Marked 57 Marketing Plan 57 Design 57 Operational Plan 57 Financial Plan 58 Risks/Challenges 59 Health, Safety and Environment aspect
regarding production, use and disposal 60 Collect, shred and sell 60
Product 60 Marked 60 Marketing Plan 60 Operational Plan 60 Financial Plan 61 Risks/Challenges 62 Health, Safety and Environment aspect
regarding production, use and disposal 63 Collect and produce simple items 63
Product 63 Marked 63 Marketing Plan 63 Design 63 Operational Plan 63 Financial Plan 64 Risks/Challenges 65 Health, Safety and Environment aspect
regarding production, use and disposal 65
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Melt and mould
Product
Suggested products; chairs, tables, roof plates, water tanks, wash basins
Marked
There is high demand for simple chairs both in the refugee camps and the host
communities. Chairs are also needed in schools.
Water tanks are also in high demand and are easily sold both on the open market
and through UNHCR. The main use of the water tanks will be for handwashing
in latrines.
There is high demand for building materials in the area. Suggested materials are
roof plates and wall tiles since they are versatile and can be used for many
purposes
Marketing Plan
The products needs to be introduced to the community. This can be done by organising
events where prototypes are presented and production method is explained.
Design
It is important to design furniture that is easy to produce, has good sitting
comfort, good quality and is modular for easy repair.
The roof plates could be both full size (2x1 m) and half size plates.
The wall tiles are 0.3 – 0.3 m in size.
The tank will be a 10 – 20 liter plastic water tank with a tap.
Operational Plan
Skills/training
Skilled operators and one mechanically trained operator
Equipment
The design of the plastic furniture will reflect the machines required.
Process
Shredded and washed material is feed into the production line.
Organisation
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The cooperatives will be set up in Melkadida and Dollo Ado with a total of 15 employees
per site.
Financial Plan
Costs has been calculated using plastic amount estimates in this report. All costs are in
USD. Assumed costs for raw material is:
- PET bottles $ 0.15/kg (4 Birr)
- Jerry cans $ 0.5/kg (15 Birr)
Investment Cost
Investment Costs in USD ($) Assumptions
Machines 10,300 See table in report, investment costs machines
Power supply 60,000 See table in report, investment costs machines
Training 3000
transport 40,000 Need to acquire one lorry per site for collection of plastic raw material
Total investment costs 113,300
Monthly costs
Amount of produce is estimated on the basis of what is realistic to make in a given time.
This can vary. The costs of seedling- and plant pots will be calculated when final design
is chosen.
Activity Costs per month (USD $) Assumptions
Labour 600 15 workers, pay $1.5/day
PET bottles
Plastic chairs
32
216 kg PET bottles to make 60 chairs. Raw material will be bought from the other cooperatives or private collectors
Plastic tables
38 252 kg PET to make 60 tables. Raw material will be bought from the other cooperatives or private collectors
Jerry cans
Roof sheets
1100 2,200 kg jerry cans to make 200 roof plates. Raw material will be bought from the other cooperatives or private collectors
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Activity Costs per month (USD $) Assumptions
Wall tiles
200
400 kg jerry cans to make 200 wall tiles. Raw material will be bought from the other cooperatives or private collectors
Water tanks
24
48 kg jerry cans to make 40 water tanks. Raw material will be bought from the other cooperatives or private collectors
Wash basins
150 300 kg jerry cans to make 100 wash basins. Raw material will be bought from the other cooperatives or private collectors
Other costs 300 Electricity, maintenance, transport
Total costs 2,444 Costs will vary with amount of produce
Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
Roof plates 11 200 2,200
Wall tiles 5 200 1,000
Chairs 11 60 660
Tables 13 60 780
Water tanks 4 40 160
Wash basins 2 100 200
Total income 5,000
The total balance in the project is positive USD 2,556.
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
- The challenge with the tank and the roof plates are to get good quality products.
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Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health A good chair is good for physical health
Roof plates and wall tiles gives dry housing
Water tanks and wash basins increases hand hygiene.
Careful that possible harmful fumes are not inhaled during production
Safety Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
Collect, shred and sell
Product
The shredded plastic can be sold externally or internally to the Coop for local production
Marked
There is a market in the bigger cities to sell the plastics to factories that produce
plastic articles
Marketing Plan
Important to find the best market price and transport for the sorted and shredded plastic
Operational Plan
Skills/training
Skilled operators
Equipment
Shredder and washer
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Process
Plastic is collected, sorted, washed and shredded
Organisation
Six sites (one in each camp + Dollo Ado) with six employees on each site. A
total of 36 employees.
Financial Plan
All costs are in USD. Assumed costs for raw material is:
- PET bottles $ 0.15/kg (4 Birr)
- Jerry cans $ 0.5/kg (15 Birr)
Assumed selling price of shredded and washed raw material is:
- PET bottles $ 0.45/kg (12 Birr)
- Jerry cans $ 0.9/kg (25 Birr)
The financial plan is made for all of the six sites put together.
Investment Cost
Investment Costs in USD
($) Assumptions
Machines 4,000 See table in report, investment costs machines
Power supply 12,000 See table in report, investment costs machines
transport 7,200 Donkey cart investment for the collection and processing plants. One cart including a donkey is 1,200 USD
Training 3000 Estimate
Total investment costs 26,200
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Monthly costs
Activity Costs per month (USD $) Assumptions
Labour 1440 all sites
6 employees per site, 36 employees in total, pay $2/day
PET bottles
675 4,500 kg bottles collected. Amount of PET bottles are based on calculated PET waste.
Jerry cans
11,500 23,000 kg jerry cans collected. Amount of jerry cans are based on calculated jerry can waste..
Other costs
400 Electricity, maintenance, transport
Total costs
14,015
Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
PET bottles 0.45 4,050* 1,823
Jerry cans 0.9 20,700* 18,630
Total income all sites 20,453
*Assuming 10% production waste
The total balance in the project is positive USD 6,438.
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
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Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health Reduce exposure to dangerous fumes by no longer burning plastic
Safety Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
Collect and produce simple items
Product
These are articles that are simple to produce like ropes, bags, brooms and mats
and also articles that are pure artistic.
Marked
There is a high demand locally for household items like ropes, brooms and mats.
For more artistic products there is also demand trough UNHCR as "products with
a story to tell"
Marketing Plan
Important to find the best market price and design for the products
Design
The design of the products will be explored during the implementation phase of
the project.
Operational Plan
Skills/training
Skilled operators/artists needs training on how to make the articles
There is already a lot of skill in the community
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Equipment
A simple shredder and moulding equipment for more complex things
No machines needed for products that does not need melting and remoulding
Process
Plastic is collected, sorted, washed and processed either by melting and
remoulding or by remoulding without melting.
Organisation
Depending on demand it is possible to set up one or more cooperatives. The
cooperatives can be organized in groups of 10 people. Workers are payed by
numbers of sales and not as employees.
Financial Plan
The financial plan is made per cooperative. Monthly costs must be calculated once the
design of the products are in place. Since the workers will get paid by number of sales,
there will be no labour costs. Amount sold and selling price are estimates for selected
items.
All costs are in USD. Assumed costs for raw material is:
- PET bottles $ 0.15/kg (4 Birr)
- Jerry cans $ 0.5/kg (15 Birr)
- Plastic bags $ 0,1/bag (3 birr)
Investment Cost
Investment Costs in USD
($) Assumptions
Machines 3900 Assuming acquiring a shredder and an oven. It is also a possibility to not use machines
Power supply 6000 Assuming acquiring a shredder and an oven
Donkey cart 1,200 One donkey cart investment for collection of plastic raw materials
Training 5000 Estimate
Total investment costs 16,100
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Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
Rope 10 m 14 20 280
Bags 7 10 70
Mats 11 20 220
Broom 11 20 220
Total income all sites 790
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health Reduce exposure to dangerous fumes by no longer burning plastic
Safety Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
Ecobricks – building houses from plastic bottles filled
with sand
Product
The product will be supplying sorted clean bottles filled with sand and the service
of building a house or other structures
Marked
UNHCR are planning to build permanent stone brick shelters for the refugees.
An option could be to build some of the houses from Ecobricks.
The refugees should get some incentives to choose the Ecobrick house.
Another alternative is to build community houses from Ecobricks
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A pilot project where different houses are built to introduce the concept to the
refugees.
Design
The design of the houses/structures should be explored during the
implementation phase of the project.
Operational Plan
Skills/training
Skilled operators needs training on how to make the houses
There is already a lot of skilled masons in the community
Equipment
No machines needed for this business, only small tools
Cement
Process
Plastic PET bottles is collected, sorted and transported to the building site. The
bottles will be filled with sand and the house constructed
Organisation
Depending on demand it is possible to set up one or more cooperatives. The
cooperatives can be organized in groups of six people.
Financial Plan
The financial plan is made per cooperative. All costs are in USD. Assumed costs for raw
material is:
- PET bottles $ 0.15/kg (4 Birr)
- Cement $ 0.18/kg (5 Birr/kg – 500 Birr/Quital, incl. transport costs
from Addis Ababa)
Investment Cost
Investment Costs in USD ($) Assumptions
Prototypes 800 Lorry 40,000 One lorry per cooperative
Training 3000 Equipment 200
Total investment costs 43,800
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The monthly costs are based on the cooperative building 20 houses/month. In one house
it is estimated to be 60% bottle bricks and 40% cement-sand mix.
Monthly costs
Activity Costs per month (USD $) Assumptions
Labour 240 6 employees per site, pay $2/day
PET bottles
144 To build one house that is 18 m2 you need approximately 4000 bottles* this equals approximately 48 kg**.
Cement 3,960 The total amount of cement per house is 1,100 kg using a sand/cement ratio of 3:1.
Other costs
200 Small equipment
Total costs
4,544
*The calculations are based on a report from EWB Australia who did a small scale pilot.
**Based on one 0.5 litre bottle weighing 12 grams
Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
House 18 m2 400 20 8,000
Total income all sites 8,000
The total balance in the project is positive USD 3,456.
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
- It must be an incentive for the refugees to choose a plastic bottle house before a
stone brick house, which they are used to.
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Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health Reduce exposure to dangerous fumes by no longer burning plastic bottles
Strong and safe shelters
Safety Solid house Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
If the bottles are not handled correctly if/when the house is demolished
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Appendix C
BUSINESS PLANS JIJIGA
Melt and mould 70
Product 70 Marked 70 Marketing Plan 70 Design 70 Operational Plan 70 Financial Plan 71 Risks/Challenges 72 Health, Safety and Environment aspect
regarding production, use and disposal 73 Collect, shred and sell 73
Product 73 Marked 73 Marketing Plan 73 Operational Plan 73 Financial Plan 74 Risks/Challenges 75 Health, Safety and Environment aspect
regarding production, use and disposal 76 Collect and produce simple items 76
Product 76 Marked 76 Marketing Plan 76 Design 76 Operational Plan 76 Financial Plan 77 Risks/Challenges 78 Health, Safety and Environment aspect
regarding production, use and disposal 78 Ecobricks – building houses from plastic bottles filled
with sand 78 Product 78 Marked 78 Design 79 Operational Plan 79 Financial Plan 79 Risks/Challenges 80 Health, Safety and Environment aspect
regarding production, use and disposal 81
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Melt and mould
Product
Suggested products; chairs, tables, roof plates, wash basins
Marked
There is high demand for simple chairs both in the refugee camps and the host
communities. Chairs are also needed in schools.
There is high demand for building materials in the area. Suggested materials are
roof plates and wall tiles since they are versatile and can be used for many
purposes
Marketing Plan
The products needs to be introduced to the community. This can be done by organising
events where prototypes are presented and production method is explained.
Design
It is important to design furniture that is easy to produce, has good sitting
comfort, good quality and is modular for easy repair.
The roof plates could be both full size (2x1 m) and half size plates.
The wall tiles are 0.3 – 0.3 m in size.
Operational Plan
Skills/training
Skilled operators and one mechanically trained operator
Equipment
The design of the plastic furniture will reflect the machines required.
Process
Shredded and washed material is feed into the production line.
Organisation
The cooperatives will be set up in Kebribeyah and Sheder with a total of 15 employees
per site.
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Financial Plan
Costs has been calculated using plastic amount estimates in this report. Costs are
calculated per site. All costs are in USD. Assumed costs for raw material is:
- PET bottles $ 0.15/kg (4 Birr)
- Jerry cans $ 0.5/kg (15 Birr)
Investment Cost
Investment Costs in USD ($) Assumptions
Machines 10,300 See table in report, investment costs machines for 2 production sites
Power supply 60,000 See table in report, investment costs machines
Training 3000
transport 40,000 Need to acquire one lorry per site for collection of plastic raw material
Total investment costs 113,300
Monthly costs
Amount of produce is estimated on the basis of what is realistic to make in a given time.
This can vary. The costs of seedling- and plant pots will be calculated when final design
is chosen. Costs are calculated per site.
Activity Costs per month (USD $) Assumptions
Labour 600 15 workers, pay $1.5/day
PET bottles
Plastic chairs
32
216 kg PET bottles to make 60 chairs. Raw material will be bought from the other cooperatives or private collectors
Plastic tables
38 252 kg PET to make 60 tables. Raw material will be bought from the other cooperatives or private collectors
Jerry cans
Roof sheets
1100 2,200 kg jerry cans to make 200 roof plates. Raw material will be bought from the other cooperatives or private collectors
Wall tiles
200
400 kg jerry cans to make 200 wall tiles. Raw material will be bought from the other cooperatives or private collectors
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Wash basins
150 300 kg jerry cans to make 100 wash basins. Raw material will be bought from the other cooperatives or private collectors
Other costs 300 Electricity, maintenance, transport
Total costs 2,420 Costs will vary with amount of produce
Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
Roof plates 11 200 2,200
Wall tiles 5 200 1,000
Chairs 11 60 660
Tables 13 60 780
Wash basins 2 100 200
Total income 4,840
The total balance in the project is positive USD 2,420.
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
- The challenge with the tank and the roof plates are to get good quality products.
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Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health A good chair is good for physical health
Roof plates and wall tiles gives dry housing
Careful that possible harmful fumes are not inhaled during production
Safety Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
Collect, shred and sell
Product
The shredded plastic can be sold externally or internally to the Coop for local production
Marked
There is a market in the bigger cities to sell the plastics to factories that produce plastic
articles
Marketing Plan
Important to find the best market price and transport for the sorted and shredded plastic
Operational Plan
Skills/training
Skilled operators
Equipment
Shredder and washer
Process
Plastic is collected, sorted, washed and shredded
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Organisation
Two sites with six employees on each site. A total of 12 employees.
Financial Plan
All costs are in USD. Assumed costs for raw material is:
- PET bottles $ 0.15/kg (4 Birr)
- Jerry cans $ 0.5/kg (15 Birr)
Assumed selling price of shredded and washed raw material is:
- PET bottles $ 0.45/kg (12 Birr)
- Jerry cans $ 0.9/kg (25 Birr)
The financial plan is made for all of the two sites put together.
Investment Cost
Investment Costs in USD
($) Assumptions
Machines 8,000 See table in report, investment costs machines
Power supply 24,000 See table in report, investment costs machines
transport 2,400 Donkey cart investment for the collection and processing plants. One cart including a donkey is 1,200 USD
Training 3000 Estimate
Total investment costs 37,400
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Monthly costs
Activity Costs per month (USD $) Assumptions
Labour 480
6 employees per site, 12 employees in total, pay $2/day
PET bottles
450 3,000 kg bottles collected. Amount of PET bottles are based on calculated PET waste.
Jerry cans
3,500 7,000 kg jerry cans collected. Amount of jerry cans are based on calculated jerry can waste.
Other costs
400 Electricity, maintenance, transport
Total costs
4,830
Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
PET bottles 0.45 2,700* 1,215
Jerry cans 0.9 6,300* 5,670
Total income all sites 6,885
*Assuming 10% production waste
The total balance in the project is positive USD 2,055.
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
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Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health Reduce exposure to dangerous fumes by no longer burning plastic
Safety Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
Collect and produce simple items
Product
These are articles that are simple to produce like ropes, bags, brooms and mats
and also articles that are pure artistic.
Marked
There is a high demand locally for household items like ropes, brooms and mats.
For more artistic products there is also demand trough UNHCR as "products with
a story to tell"
Marketing Plan
Important to find the best market price and design for the products
Design
The design of the products will be explored during the implementation phase of
the project.
Operational Plan
Skills/training
Skilled operators/artists needs training on how to make the articles
There is already a lot of skill in the community
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Equipment
A simple shredder and moulding equipment for more complex things
No machines needed for products that does not need melting and remoulding
Process
Plastic is collected, sorted, washed and processed either by melting and
remoulding or by remoulding without melting.
Organisation
Depending on demand it is possible to set up one or more cooperatives. The
cooperatives can be organized in groups of 10 people. Workers are payed by
numbers of sales and not as employees.
Financial Plan
The financial plan is made per cooperative. Monthly costs must be calculated once the
design of the products are in place. Since the workers will get paid by number of sales,
there will be no labour costs. Amount sold and selling price are estimates for selected
items.
All costs are in USD. Assumed costs for raw material is:
- PET bottles $ 0.15/kg (4 Birr)
- Jerry cans $ 0.5/kg (15 Birr)
- Plastic bags $ 0,1/bag (3 birr)
Investment Cost
Investment Costs in USD
($) Assumptions
Machines 3900 Assuming acquiring a shredder and an oven. It is also a possibility to not use machines
Power supply 6000 Assuming acquiring a shredder and an oven
Donkey cart 1,200 One donkey cart investment for collection of plastic raw materials
Training 5000 Estimate
Total investment costs 16,100
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Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
Rope 10 m 14 20 280
Bags 7 10 70
Mats 11 20 220
Broom 11 20 220
Total income all sites 790
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health Reduce exposure to dangerous fumes by no longer burning plastic
Safety Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
Ecobricks – building houses from plastic bottles filled
with sand
Product
The product will be supplying sorted clean bottles filled with sand and the service
of building a house or other structures
Marked
UNHCR are planning to build permanent stone brick shelters for the refugees.
An option could be to build some of the houses from Ecobricks.
The refugees should get some incentives to choose the Ecobrick house.
Another alternative is to build community houses from Ecobricks
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A pilot project where different houses are built to introduce the concept to the
refugees.
Design
The design of the houses/structures should be explored during the
implementation phase of the project.
Operational Plan
Skills/training
Skilled operators needs training on how to make the houses
There is already a lot of skilled masons in the community
Equipment
No machines needed for this business, only small tools
Cement
Process
Plastic PET bottles is collected, sorted and transported to the building site. The
bottles will be filled with sand and the house constructed
Organisation
Depending on demand it is possible to set up one or more cooperatives. The
cooperatives can be organized in groups of six people.
Financial Plan
The financial plan is made per cooperative. All costs are in USD. Assumed costs for raw
material is:
- PET bottles $ 0.15/kg (4 Birr)
- Cement $ 0.18/kg (5 Birr/kg – 500 Birr/Quital, incl. transport costs
from Addis Ababa)
Investment Cost
Investment Costs in USD ($) Assumptions
Prototypes 800 Lorry 40,000 One lorry per cooperative
Training 3000 Equipment 200
Total investment costs 43,800
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The monthly costs are based on the cooperative building 20 houses/month. In one house
it is estimated to be 60% bottle bricks and 40% cement-sand mix.
Monthly costs
Activity Costs per month (USD $) Assumptions
Labour 240 6 employees per site, pay $2/day
PET bottles
144 To build one house that is 18 m2 you need approximately 4000 bottles* this equals approximately 48 kg**.
Cement 3,960 The total amount of cement per house is 1,100 kg using a sand/cement ratio of 3:1.
Other costs
200 Small equipment
Total costs
4,544
*The calculations are based on a report from EWB Australia who did a small scale pilot.
**Based on one 0.5 litre bottle weighing 12 grams
Income (pr. month)
Product selling price (USD $) amount sold Revenue (USD $)
House 18 m2 400 20 8,000
Total income all sites 8,000
The total balance in the project is positive USD 3,456.
Risks/Challenges
- Shortage of raw material
- Not enough sales
- Not enough production
- It must be an incentive for the refugees to choose a plastic bottle house before a
stone brick house, which they are used to.
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Health, Safety and Environment aspect regarding
production, use and disposal
Positive Negative
Health Reduce exposure to dangerous fumes by no longer burning plastic bottles
Strong and safe shelters
Safety Solid house Injuries during production
Environment Reuse of waste plastic
Reduction of waste
Positive effect on the environment
If the bottles are not handled correctly if/when the house is demolished
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Appendix D
BILL OF QUANTITY
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Appendix E
FACTORY AND COLLECTION POINT SET UP
- Calculation of shredder
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The layout in the factories is suggested as shown in the following figures.
Factory setup in Jijiga area
Setup for shredding and washing point in Jijiga area
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Setup for factories in Melkadida area
Setup for shredding and washing points in Melkadida area
Assessment of size of shredder
Estimate from Solid Waste technology and management
As written in the general chapter on recycling technology globally, production of 1000 kg
shredded plastic uses 340 kWh. For PET-bottles 340 kWh is probably a bit too low, because in
general more energy is needed to shred 1 kg of material if the material is less dense, and this
estimate is for HDPE. Still, this estimate is used, both because there is a little amount of PET
compared to HDPE cans in weight, and also the process is not expected to be as good as in
factories working on a big scale with complicated machines.
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Document no.: 2018002-R Date: 2018-08-20 Rev.no.: 0 Page: 88 In Jijiga there are 10 000 kg each month to be shredded in three different sites. An equal split
of material is assumed in this analysis, and this gives a need of 3 300 kg to be shredded in each
site. 3 300 kg gives an energy use of 340 kWh x 3.3 = 1 100 kWh in each of the sites. When
assuming that the plant will run for 8 hours 20 working days in a month, this gives a capacity
need of 1 100 kWh / (8 h x 20) = 6.9 kW =>7 kW.
In Melkadida area, the amount is 30 000 kg of plastic each month, divided into 6 receiving
points. That gives a average need for shredding of 5 000 kg in each location each month. The
installed capacity needed in each of the locations in Melkadida is therefore 340 kWh x 5 = 1700
kWh -> 1700 kWh / (8 h x 20) = 10.6 kW installed capacity.
Shredding plant in Addis Ababa
This is controlled with numbers given from a shredding plant visited in Addis Ababa. They
receive 100.000 bottles per month, and have a 75 kW shredding machine. That is 10 times more
than each of the loction in Jijiga will need to shred, and it is assumed that a ten times smaller
machine would have been sufficient. This is a 7,5 kW machine, and 7 kW therefore seems like
a good estimate, taken into account that the working hours during a week is planned to be
shorter in Jijiga than in Addis.
Daadab refugee camp
We have also been informed that the shredder used in Daadab refugee camp in Kenya is ca. 20
kW, and can take 3 tons per day. Hence, the shredder Precious Plastic have made with about
2kW capacity, can probably take up to 300 kg plastic per day. In Jjijiga, which have an
estimated amount of 3.300 kg/month per receiving point, an average of 165 kg plastiv should
be shredded every day with 20 working days a month. A capacity of 300 kg per day is almost
twice as much as needed. Hence, according to this estimate, only 1 kW installed capacity is
almost sufficient to shred all the plastic in these camps.
In Melkadida, the total plastic amount is estimated to be 30.000 kg each month, and this gives
the six receiving points a need to shred approximately 5.000 kg every month. This is almost
two times more than the estimate for each collecting point in Jijiga, less than 2 kW installed
capacity on the shredders are sufficient here, according to the estimates from Daadab camp.
Conclusion
Since the two first estimates give approximately the same answer, and the third estimate gives
a much lower installed capacity need, it is decided to use the estimates that have two different
sources giving the same answer. This is also better to use, because it is better with a too high
cost estimate than too low.