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Tees Valley Resource Efficiency Club Half Day Workshop Waste Management


save lost production time spent on maintenance and breakdowns. reduce waste disposal costs ... keep a site diary and logbook of all waste movements ... – PowerPoint PPT presentation

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Title: Tees Valley Resource Efficiency Club Half Day Workshop Waste Management

Tees Valley Resource Efficiency Club Half Day
Workshop Waste Management
Andy Rogers Principal Consultant Atkins
  • Toilets
  • Fire escapes/exits
  • Fire alarm test?
  • Breaks tea/coffee
  • Lunch

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

  • One Minute Introductions

Sharing Knowledge Saving Resources
Waste Management ..... or do we really mean
Waste Minimisation ....??
  • What is Waste?

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

All Companies produce waste - even efficient ones
Sharing Knowledge Saving Resources
  • 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
  • What is Waste Minimisation?

Sharing Knowledge Saving Resources
  • 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.

Sharing Knowledge Saving Resources
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
Sharing Knowledge Saving Resources
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

Sharing Knowledge Saving Resources
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

Sharing Knowledge Saving Resources
The True Cost of Waste
Sharing Knowledge Saving Resources
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
  • Disposal should only be the last resort

Sharing Knowledge Saving Resources
The Waste Hierarchy
Sharing Knowledge Saving Resources
Waste Minimisation
  • Six key steps for a systematic approach to
    reducing waste

Sharing Knowledge Saving Resources
  • 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

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
Sharing Knowledge Saving Resources
  • 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

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
Sharing Knowledge Saving Resources
  • 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
  • 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.
Sharing Knowledge Saving Resources
  • 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.
Sharing Knowledge Saving Resources
  • 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
  • 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.
Sharing Knowledge Saving Resources
  • 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

Sharing Knowledge Saving Resources
  • 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
  • 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

Sharing Knowledge Saving Resources
Actions to Reduce Waste
  • This may include redesign

1. Can you eliminate waste at source?
2. Can you reduce the amount of waste produced?
3. Can you re-use any waste?
4. Can you recycle/recover any waste?
5. Determine proper disposal route and calculate
Implement waste minimisation
Sharing Knowledge Saving Resources
Systematic Approach to Continuous Improvement
Sharing Knowledge Saving Resources
  • If you dont measure it ..........
  • you cant manage it!

Sharing Knowledge Saving Resources
Actions to Reduce Waste
  • Waste Management - What Next?
  • There are ready-made checklists and assessment
    tools available
  • See Envirowise Guides the Further Help
  • www.envirowise.gov.uk

Sharing Knowledge Saving Resources
Actions to Reduce Waste - Opportunity Checklist
Sharing Knowledge Saving Resources
Actions to Reduce Waste - Opportunity Checklist
Sharing Knowledge Saving Resources
Actions to Reduce Waste - Action Plan
Sharing Knowledge Saving Resources
Actions to Reduce Waste - Training Needs Matrix
Sharing Knowledge Saving Resources
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
  • 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
Sharing Knowledge Saving Resources
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
  • 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

Sharing Knowledge Saving Resources
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
  • 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.

Sharing Knowledge Saving Resources
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.

Sharing Knowledge Saving Resources
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.

Sharing Knowledge Saving Resources
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

Sharing Knowledge Saving Resources
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.

Sharing Knowledge Saving Resources
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

Sharing Knowledge Saving Resources
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,
  • 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

Sharing Knowledge Saving Resources
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
  • http//www.defra.gov.uk/environment/waste/legislat

Site Waste Management Plans are now a legal
requirement for all construction sites
Sharing Knowledge Saving Resources
Compliance with Environmental Legislation
  • Compliance with the Duty of Care
  • ensure that all wastes are stored safely and
  • check that all waste contractors have the
    appropriate licences
  • fill out waste transfer notes properly
  • fill out consignment notes for hazardous waste
  • keep copies of all waste transfer notes for two
  • http//www.netregs.gov.uk/netregs/275207/276510/27

Sharing Knowledge Saving Resources
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/

Sharing Knowledge Saving Resources
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
  • details of any broker involved in the transfer of
    the waste

Sharing Knowledge Saving Resources
Compliance with Environmental Legislation
  • Practical Aspects of securing Compliance with the
    Duty of Care requirements
  • keep a site diary and logbook of all waste
  • keep copies of all waste licences, waste transfer
    notes and consignment notes
  • link payments to final copies of waste transfer
  • 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
  • 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

Sharing Knowledge Saving Resources
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
  • Environment Agency
  • SEPA
  • Environment and Heritage Service Northern Ireland

Sharing Knowledge Saving Resources
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
  • fluorescent light tubes
  • lead-acid batteries
  • oily sludges
  • pesticides
  • solvents

Sharing Knowledge Saving Resources
  • 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

Sharing Knowledge Saving Resources
  • 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
  • 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

Sharing Knowledge Saving Resources
Sharing Knowledge Saving Resources
  • Your Waste Minimisation Programme - Rules for
  • 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
  • integrate waste minimisation into existing
    management systems

Sharing Knowledge Saving Resources
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

Sharing Knowledge Saving Resources
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

Sharing Knowledge Saving Resources
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

Motivating managers
  • Senior Managers
  • Reduced costs
  • Reduced risks of prosecution and financial
  • Improved company image
  • Avoided reputational risks
  • Help to combat supply chain pressures, (eg

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

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

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

Develop a Communication Strategy
  • What do you want to achieve?
  • Who can assist?
  • How can you motivate people?

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

Communication Formats
  • Text
  • Pictures/cartoons
  • Graphs
  • Presentations

  • 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

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

Useful Websites
www.netregs.gov.uk www.envirowise.gov.uk www.eca-
water.gov.uk www.environment-agency.gov.uk www.def
TVREC Members Resource Efficiency Reporting
Sharing Knowledge Saving Resources
Resource Efficiency Reporting
  • Report on Resource Efficiency savings
  • Projected
  • resource, e.g., kWh electricity
  • financial savings
  • Actual
  • resource, e.g., kWh electricity
  • financial savings

Sharing Knowledge Saving Resources
The Future of the Tees Valley Resource Efficiency
Club - Discussion
Sharing Knowledge Saving Resources
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!

Sharing Knowledge Saving Resources
Any Other Business
Sharing Knowledge Saving Resources
Contact Details
  • Andy Rogers
  • Principal Consultant
  • 01332 225740/ 07803 260767
  • Andy.Rogers_at_atkinsglobal.com
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