Tees Valley Resource Efficiency Club Half Day Workshop Waste Management

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Tees Valley Resource Efficiency Club Half Day
WorkshopWaste Management
Andy Rogers Principal Consultant Atkins
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Domestics

• Toilets
• Fire escapes/exits
• Fire alarm test?
• Breaks tea/coffee
• Lunch

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Agenda

• Introductions
• Waste Management
• Resource Efficiency Reporting Session
• The Future of the Tees Valley Resource Efficiency
  Club - Discussion
• Any Other Business
• Lunch

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Introductions

• One Minute Introductions

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Waste Management..... or do we really mean
Waste Minimisation ....??
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Question

• What is Waste?

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Definitions

• refuse (solid waste, trade waste, etc)
• waste packaging
• water
• effluent
• waste oils, solvents, liquid residues in drums,
  etc
• smoke and fumes
• heat/energy losses
• rejects and rework
• wasted effort

All Companies produce waste - even efficient ones
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Definitions

• Waste
• loss of valuable company assets
• any substance or object...which the producer or
  the person in possession of it discards or
  intends or is required to discard

This is the legal definition
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Definitions

• What is Waste Minimisation?

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Definitions

• Waste minimisation is a management technique that
  can be defined as
• The application of a systematic approach to
  reducing the generation of waste at source.
• Waste is produced from all parts of an
  organisation. Waste minimisation is about
  optimising all areas of the business to be more
  resource efficient and thus prevent, or at least
  minimise, the production of waste.

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Waste Minimisation

• How will reducing waste help your business?
• cost savings from reduced raw material and waste
  disposal costs - typically 1 of business
  turnover or 1000 per employee can be saved
• improved process performance
• improved environmental performance
• compliance with legislation and reduced risk of
  environmental incidents
• commercial and strategic advantages - it can make
  your company more competitive and improve its
  standing with customers who seek assurance that
  their suppliers are operating on a sound
  environmental basis

The actual cost of waste to UK companies is
typically 4 - 5 of turnover and in many cases
it can be as high as 10
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Waste Minimisation

• Specific benefits to employees include
• improved working conditions
• cost savings (typically 1 000 per employee),
  giving money that can be spent on other things
  such as training
• motivation
• team working
• feel good factor within the company
• improved recruitment and retention of staff

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Waste Disposal Costs

• Waste disposal costs are just the tip of the
  iceberg - the hidden costs include the cost of
  raw materials, energy, labour, etc. To assess the
  true cost of waste and achieve maximum savings,
  the hidden costs need to be identified and
  quantified

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The True Cost of Waste
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The Waste Hierarchy

• The principles underlying good waste minimisation
  practice are based on the waste hierarchy
• This is the order of preference for reducing
  waste and is based on the fact that prevention is
  better than cure
• Focusing on the top levels of the waste hierarchy
  will enable companies to achieve optimum benefits
• It is through careful purchase and better use of
  resources that companies will make the most
  dramatic savings in the cost of waste
• Recycling should be considered once ways to
  eliminate, reduce and re-use waste have been
  investigated
• Disposal should only be the last resort

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The Waste Hierarchy
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Waste Minimisation

• Six key steps for a systematic approach to
  reducing waste

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• Identify how much waste your company is
  generating and the costs involved
• Produce a simple list of resources, raw materials
  and utilities used by your company and the kinds
  of waste generated in your processes
• Assess key cost areas for attention
• This list or assessment is your initial
  performance base-line that can be used as an
  indicator against which to measure your future
  progress

You may find that utility bills, invoices, etc.,
from your accounts department can help you to
find much of the information you need for your
list or assessment
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• When you have compiled your list or assessment,
  you can compare your performance with that of
  other companies in your industry
• Benchmarking Guides, available through the
  Environment and Energy Helpline, can help you to
  set realistic goals for reducing the cost of your
  waste

Case Studies, available through the Environment
and Energy Helpline, show how companies of
varying sizes and from different sectors of
industry have benefited from actively measuring
and reducing their waste. Many of the ideas they
contain for simple changes leading to substantial
savings may be appropriate for your company
- even if they operate in a different industry
sector.
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• Once you have established how much waste is
  actually costing your company, you can begin to
  identify the key areas in which to take action
• To gain more detail about where waste is
  occurring, you need to understand what is
  involved at each stage of the process or
  processes undertaken by your organisation
• Walk around the site looking for areas where
  waste is being generated and talk to key
  personnel
• From this practical information, develop a plan
  of ideas to take to senior management

Staff operating each stage of the process
are the best source of information regarding the
waste produced and ideas for improvement. Just
because something has always been done in a
certain way doesnt mean it is the best way of
doing it.
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• When you have made your plan, you are ready to
  present your case to senior management
• Convince them of the potential cost benefits of
  reducing waste and obtain their commitment to
  providing the necessary resources for
  implementing a Waste Minimisation Action Plan
• Start building a team and holding brainstorming
  sessions with staff to generate ideas for ways to
  improve performance and competitiveness

Do not underestimate the importance of senior
management commitment as this can mean the
difference between success or failure, no matter
how good your plan.
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• Once you have gained senior management commitment
  and built a team, you can take your plan and turn
  it into an Action Plan
• Start by identifying obvious areas of waste
  reduction where immediate and substantial savings
  can be achieved by implementing no-cost and
  low-cost measures
• Make sure the Action Plan is agreed, written and
  recorded
• Use it to take action and start to achieve cost
  savings and environmental benefits

Implement good housekeeping measures, including
a checklist, for every area. Use meters
to obtain accurate data and ensure that they are
checked regularly. These simple changes can
help you to identify where leaks, wastes and
problems may be wasting money.
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• Once you have implemented your Action Plan and
  savings have been achieved, return to your
  original performance base-line assessment and
  measure the progress you have made
• It should be easy to identify the cost savings
• Feed back successes and achievements to senior
  management and staff in order to maintain
  motivation and enthusiasm for the plan
• This is important for continued waste reduction
  in your company
• Waste reduction is an on-going process

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• You now have the basis for a systematic approach
  to continuous improvement
• Progress should be reviewed at regular intervals
  and the targets and Action Plan revised
  accordingly
• Continue to compare your performance with that of
  your competitors
• Even if your performance matches that of the most
  efficient companies, there may still be room for
  improvement and additional cost savings

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Actions to Reduce Waste

• This may include redesign

1. Can you eliminate waste at source?
Yes
No
2. Can you reduce the amount of waste produced?
No
3. Can you re-use any waste?
No
4. Can you recycle/recover any waste?
No
5. Determine proper disposal route and calculate
cost
Implement waste minimisation
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Systematic Approach to Continuous Improvement
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Remember!

• If you dont measure it ..........
• you cant manage it!

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Actions to Reduce Waste

• Waste Management - What Next?
• There are ready-made checklists and assessment
  tools available
• See Envirowise Guides the Further Help
  slides.
• www.envirowise.gov.uk

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Actions to Reduce Waste - Opportunity Checklist
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Actions to Reduce Waste - Opportunity Checklist
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Actions to Reduce Waste - Action Plan
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Actions to Reduce Waste - Training Needs Matrix
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Waste Management - Examples

• Coffee manufacturer - contract with a
  well-known Waste Disposal Contractor
• Solid waste collected in skips with fixed price
  skip collection - not related to weight
• Collection frequency not specified - call off
  basis
• Waste management exercise identified huge
  variability in skip weights when removed (500 kg
  - 6 tonnes) ...???
• No-one was managing the Waste Contractor - they
  decided when to empty skips
• Waste Contractor was using it as a fill-in - if
  things were quiet, theyd come in and lift a skip
  and levy the charge

Saving thousands
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Waste Management - Examples

• A Case Study at Kappa Packaging
• This Case Study demonstrates the economic and
  environmental benefits of effective measurement
  of waste as a tool to achieve significant process
  improvement. When a waste review showed that
  existing waste data were incomplete, Kappa
  Packaging introduced a waste reporting system to
  provide accurate records of process waste and to
  achieve greater control of waste arisings. At the
  same time, continual improvement teams undertook
  a range of projects to reduce waste and achieve
  performance targets. The benefits of measuring
  waste properly across the business and the
  initiatives undertaken include
• Cost savings of over 199 000/year by the end of
  2002
• Cost savings of 0.8 of turnover, or over 1 000
  per employee
• Reduction in process waste by over 10
• Raised staff awareness regarding the quantity and
  cost of waste

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Waste Management - Examples

• Lubricants
• Poorly managed oil systems can cost a lot of
  money, often in hidden costs, such as through
  avoidable machine breakdowns. With good control,
  oil use can be minimised and considerable savings
  made.
• Lubricants are vital, yet often overlooked,
  resources for the
• engineering industry. An effective management
  programme can
• bring cost benefits from reduced consumption
• save lost production time spent on maintenance
  and breakdowns
• reduce waste disposal costs
• reduce environmental risk
• Fords Dagenham plant introduced a systematic
  oil management programme and has reduced its oil
  use by 20 and reduced unscheduled machine
  stoppages for lubrication by 80.

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Waste Management - Examples

• Fisher Foods is a producer of pre-packed salad
  products and has a 45 million annual turnover.
  Raw material costs accounted for 20
  million/year. Monitoring and flow sheeting of the
  operations highlighted three areas for improved
  performance unnecessary disposal of good quality
  off-cuts, which could be incorporated in other
  products adjustment of a spin-drying process
  that reduced product damage and wastage and
  improved mechanical handling that also reduced
  product damage. These changes have resulted in
  cost savings of 400 000/year, almost 1 of
  turnover, with minimal implementation costs.

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Waste Management - Examples

• Dana Spicer Europe Ltd is a leading manufacturer
  of complete axle assemblies for heavy-duty
  commercial vehicle applications. The Leeds site
  has a 45 million annual turnover. As part of a
  more comprehensive effort to reduce wastage,
  metalworking fluid use was examined. The fluid
  life was variable due to tramp oil and dirt and
  this required frequent machine clean-down and
  fluid refills, the used fluid going for special
  waste disposal. Following initial reductions in
  disposals using an oil-water separation approach,
  a centralised fluid treatment and recycling unit
  was installed. This has reduced fluid usage by
  75. Additional benefits in reduced man-hours
  for machine cleaning give total savings of 13
  150/year, with a payback period on investment of
  21 months.

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Waste Management - Examples

• Welbeck Fabric Dyers employs 170 people at its
  Derbyshire factory and processes around 350 000
  metres/week of fabric for the fashion,
  leisurewear and lingerie markets on a commission
  dyeing basis. Faced with rising costs for water
  supply and effluent disposal, Welbeck adopted a
  systematic approach to cost and environmental
  control. Improved monitoring of water and energy
  use found that, for example, the sofcers (fabric
  conditioning units) accounted for 20 of site
  water use and were using more water than
  specified by the manufacturer. Optimising
  settings for different fabric runs has reduced
  use by over 40. Further savings have resulted
  from better housekeeping, control of cleaning
  hoses etc, and use of simple water saving
  devices. Overall savings are assessed at over 37
  000/year.

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Waste Management - Examples

• Orangebox Ltd (formerly Giroflex) specialises in
  office chair design and manufacture. The company,
  which employs 147 people, already recycles much
  of its waste but a team of production and
  development operatives, led by the Health, Safety
  and Environment Co-ordinator, has enabled the
  company to identify even more improvements by
  minimising waste production at source. Low-cost
  process changes have enabled Orangebox to save
  over 67 000/year (further savings of over 50
  000/year have been identified). The changes have
  reduced material and energy use, increased
  production capacity and reduced the amount of
  factory space needed for the production line.

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Compliance with Environmental Legislation

• Not intending to get into Waste Legislation
• Would need a full-scale training course in its
  own right
• Just a quick run through the key requirements
• What follows is not exhaustive or comprehensive

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Compliance with Environmental Legislation

• All those who produce or handle controlled waste
  have a legal responsibility under the Duty of
  Care requirements of
• Section 34 of Environmental Protection Act 1990,
  and
• The Environmental Protection (Duty of Care)
  Regulations 1991 (S.I. 1991 No.2839)
• to ensure that controlled waste is taken care of
  and passed to someone authorised to receive it
  (e.g., a Registered Waste Carrier or a Licensed
  Site)

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Compliance with Environmental Legislation

• Duty of Care
• Failure to comply can result in an unlimited fine
• Site Waste Management Plans are good practice and
  provide a framework which enables sites to
• comply with waste legislation
• manage risk
• help them to work with the Regulators
• demonstrate compliance with the law
• See Waste Management The Duty of Care A Code of
  Practice
• http//www.defra.gov.uk/environment/waste/legislat
  ion/duty.htm

Site Waste Management Plans are now a legal
requirement for all construction sites
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Compliance with Environmental Legislation

• Compliance with the Duty of Care
• ensure that all wastes are stored safely and
  securely
• check that all waste contractors have the
  appropriate licences
• fill out waste transfer notes properly
• fill out consignment notes for hazardous waste
  properly
• keep copies of all waste transfer notes for two
  years
• http//www.netregs.gov.uk/netregs/275207/276510/27
  7588/?lang_e

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Compliance with Environmental Legislation

• Practical Aspects of securing Compliance with the
  Duty of Care requirements
• check the public registers maintained by the
  Environment Agency and SEPA of all licensed waste
  carriers and brokers. These can be inspected at
  their local offices or are available online
• Environment Agency
• www.environment-agency.gov.uk/publicregister
• SEPA
• www.sepa.org.uk/regulation/rocas/

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Compliance with Environmental Legislation

• Practical Aspects of securing Compliance with the
  Duty of Care requirements
• fill in and sign waste transfer notes so that
  they include
• the appropriate six-digit European Waste
  Catalogue code
• what the waste is and how much there is
• the type of container
• the time, date and place the waste was
  transferred from
• the names and addresses of both people involved
  in the transfer
• the waste carriers registration number
• the waste licence number of the facility (if
  appropriate)
• details of any broker involved in the transfer of
  the waste

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Compliance with Environmental Legislation

• Practical Aspects of securing Compliance with the
  Duty of Care requirements
• keep a site diary and logbook of all waste
  movements
• keep copies of all waste licences, waste transfer
  notes and consignment notes
• link payments to final copies of waste transfer
  notes
• ensure staff receive appropriate training
• make sub-contractors aware of site procedures
  (particularly if they are responsible for their
  own waste)
• make spot checks on facilities and waste
  movements
• carry out audits of paperwork held (licenses,
  waste transfer notes, consignment notes)
• monitor the performance of waste contractors and
  visit their facilities
• liaise with the Regulators local office

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Compliance with Environmental Legislation

• Hazardous Waste
• If a site produces over 200 kg of hazardous
  waste, it will have to register with the
  appropriate regulator as a producer of hazardous
  waste
• Environment Agency
• SEPA
• Environment and Heritage Service Northern Ireland

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Compliance with Environmental Legislation

• Examples of hazardous waste-
• asbestos
• chemical wastes
• healthcare wastes
• electrical equipment containing hazardous
  components such as cathode ray tubes or lead
  solder
• fluorescent light tubes
• lead-acid batteries
• oily sludges
• pesticides
• solvents

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Conclusions

• It is possible to significantly reduce your costs
  and cut your waste volumes by implementing
  relatively simple measures, many with low or no
  associated cost
• Taking action today could give you the edge over
  your competitors
• You can nearly always improve an existing system
• The cost of implementing any changes that reduce
  waste volumes is likely to pay you back many
  times over

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Conclusions

• Taking action to improve your Waste Management
  will help you to
• increase overall profitability
• increase staff awareness of environmental and
  cost-saving issues
• develop closer relationships with suppliers and
  customers through shared benefits and cost
  savings
• reduce your use of finite resources
• reduce the volume of waste for management
• enhance environmental performance
• promote a better company image
• meet current or future regulatory requirements,
  at the least possible cost

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Conclusions
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Conclusions

• Your Waste Minimisation Programme - Rules for
  success
• follow the waste hierarchy
• adopt a systematic approach to data collection,
  implementing ideas, etc.,
• seek ideas and suggestions from everyone
• strive for continual improvement
• use the tools available free from Envirowise to
  help you
• maintain your waste minimisation programme
• start with no-cost and low-cost measures that
  bring quick savings - there are plenty of ideas
  in the checklists and Envirowise Guides
• broadcast success and maintain staff
  education/training
• integrate waste minimisation into existing
  management systems

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Further Help 1

• Envirowise Guides www.envirowise.gov.uk
• EN330 Measuring to manage how reducing waste can
  unlock increased profits
• GG367 Waste minimisation for managers
• EN335 Support for the engineering industry
• CS791 Effective Management and Segregation Reduce
  Hazardous Waste Disposal Costs
• GG125 Waste Minimisation Pays Five business
  reasons for reducing waste
• GG227 Cost-effective Management of Lubricating
  and Hydraulic Oils
• EN504 Introduction to the waste hierarchy

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Further Help 2

• Envirowise Guides www.envirowise.gov.uk
• EN505 Re-use waste and improve your bottom line
• EN801 Assessment Form for Hotel Rooms
• GG642 An introduction to Site Waste Management
  Plans

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General motivation how to make resource
efficiency work

• Champion
• Personal and technical development
• Ownership and management
• Access to senior management
• Considered as part of improved company performance

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Motivating managers

• Senior Managers
• Reduced costs
• Reduced risks of prosecution and financial
  liabilities
• Improved company image
• Avoided reputational risks
• Help to combat supply chain pressures, (eg
  cost-down)

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Motivating staff

• Operators
• Personal recognition
• Attributed savings
• Working within a greener company
• Possible financial rewards - link to suggestion
  schemes

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Examples of resistance

• Its going to cost money
• Negativity It wont work its a waste of time
• It cant be done any other way weve always
  done it this way
• Nobody will get involved

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How to Overcome Resistance

• Resource management saves money, typically
• 1-3 of turnover
• 5-15 of energy and water costs
• 5-10 of the true cost of waste
• Avoids potential pollution prosecution
• Examples case studies prove it works!
• All staff can identify with improving the
  environment improved team working and culture

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Develop a Communication Strategy

• What do you want to achieve?
• Who can assist?
• How can you motivate people?

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Methods of Communication

• E mail
• Notice boards/white boards
• Newsletters
• Memos
• Posters/stickers
• Intranets
• Presentations
• Item at regular team meetings
• Annual reports

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Communication Formats

• Text
• Pictures/cartoons
• Graphs
• Presentations

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Remember

• Use a method specific for your audience to get
  your point across
• Use a suitable medium to relay the message
• Be aware of the environmental implications
• Be prepared to change your approach

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Site review and action planning

• Review opportunities
• Use of costs data and process mapping to identify
  priorities
• Develop a draft action plan
• Review and continue to assess opportunities
• Project management
• Consider an environmental management system

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Useful Websites
www.netregs.gov.uk www.envirowise.gov.uk www.eca-
water.gov.uk www.environment-agency.gov.uk www.def
ra.gov.uk
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TVREC MembersResource Efficiency Reporting
Session
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Resource Efficiency Reporting

• Report on Resource Efficiency savings
• Projected
• resource, e.g., kWh electricity
• financial savings
• Actual
• resource, e.g., kWh electricity
• financial savings

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The Future of the Tees Valley Resource Efficiency
Club - Discussion
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The Future of the TVREC

• This is our final Half Day Workshop
• Now what?
• How best to utilise remaining funding
• Targeted one-to-one visits aimed at achieving
  specific savings?
• Alternative sources of funding
• One North East?
• Others?
• Thoughts and/or proposals for discussion
• TVREC is your club!

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Any Other Business
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Contact Details

• Andy Rogers
• Principal Consultant
• 01332 225740/ 07803 260767
• Andy.Rogers_at_atkinsglobal.com