Title: Tees Valley Resource Efficiency Club Half Day Workshop Waste Management
1Tees Valley Resource Efficiency Club Half Day
WorkshopWaste Management
Andy Rogers Principal Consultant Atkins
2Domestics
- Toilets
- Fire escapes/exits
- Fire alarm test?
- Breaks tea/coffee
- Lunch
3Agenda
- Introductions
- Waste Management
- Resource Efficiency Reporting Session
- The Future of the Tees Valley Resource Efficiency
Club - Discussion - Any Other Business
- Lunch
4Introductions
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5Waste Management..... or do we really mean
Waste Minimisation ....??
6Question
7Definitions
- 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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8Definitions
- 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
9Definitions
- What is Waste Minimisation?
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10Definitions
- 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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11Waste 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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12Waste 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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13Waste 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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14The True Cost of Waste
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15The 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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16The Waste Hierarchy
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17Waste Minimisation
- Six key steps for a systematic approach to
reducing waste
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18- 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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19- 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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20- 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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21- 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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22- 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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23- 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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24- 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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25Actions 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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26Systematic Approach to Continuous Improvement
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27Remember!
- If you dont measure it ..........
- you cant manage it!
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28Actions 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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29Actions to Reduce Waste - Opportunity Checklist
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30Actions to Reduce Waste - Opportunity Checklist
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31Actions to Reduce Waste - Action Plan
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32Actions to Reduce Waste - Training Needs Matrix
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33Waste 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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34Waste 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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35Waste 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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36Waste 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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37Waste 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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38Waste 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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39Waste 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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40Compliance 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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41Compliance 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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42Compliance 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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43Compliance 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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44Compliance 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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45Compliance 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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46Compliance 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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47Compliance 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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48Compliance 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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49Conclusions
- 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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50Conclusions
- 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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51Conclusions
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52Conclusions
- 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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53Further 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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54Further 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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55General 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
56Motivating 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)
57Motivating staff
- Operators
- Personal recognition
- Attributed savings
- Working within a greener company
- Possible financial rewards - link to suggestion
schemes
58Examples 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
59How 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
60Develop a Communication Strategy
- What do you want to achieve?
- Who can assist?
- How can you motivate people?
61Methods of Communication
- E mail
- Notice boards/white boards
- Newsletters
- Memos
- Posters/stickers
- Intranets
- Presentations
- Item at regular team meetings
- Annual reports
62Communication Formats
- Text
- Pictures/cartoons
- Graphs
- Presentations
63Remember
- 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
64Site 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
65Useful Websites
www.netregs.gov.uk www.envirowise.gov.uk www.eca-
water.gov.uk www.environment-agency.gov.uk www.def
ra.gov.uk
66TVREC MembersResource Efficiency Reporting
Session
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67Resource 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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68The Future of the Tees Valley Resource Efficiency
Club - Discussion
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69The 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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70Any Other Business
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71Contact Details
- Andy Rogers
- Principal Consultant
- 01332 225740/ 07803 260767
- Andy.Rogers_at_atkinsglobal.com