The European Regional Development Fund (ERDF) Resource Efficiency Training Add venue Name of advisors
The European Regional Development Fund (ERDF)
Resource Efficiency Training
Add venue
Name of advisors
ENWORKS Resource Efficiency Programme
Introductions
• Name & Job / Role
• Company name & brief description of operations
• What is your company’s major waste?
• What do you hope to get out of today?
The European Regional Development Fund (ERDF)
Module 1 - Energy
ENWORKS Resource Efficiency Programme
Learning objectives
• To gain a basic understanding of:• energy consumption• monitoring• control
• Identify potential savings & share best practice
ENWORKS Resource Efficiency Programme
Why focus on energy?
• All companies use some form of energy – gas, electricity & fuel
• Because most companies can reduce their energy bills by 20%
• Because legislation and other Government initiatives are forcing us
• Often a company’s major environmental impact
• Because £12 billion of energy is wasted in the UK every year (Action Energy)
ENWORKS Resource Efficiency Programme
Impact of electricity
• Company paying £5,000/year• Equivalent to:• 100,000 kW consumption (5p per kW)• 44 tonnes of carbon dioxide (or 12 solid
tonnes of carbon)• Volume of 250 double-decker buses (CO2)• Weight of 8.1 elephants (or 587 men)• 73,997 miles in a car using petrol at 30mpg• Running Titanic for 2.6 hours on full steam
ENWORKS Resource Efficiency Programme
What are the benefits of reducing consumption?
ENWORKS Resource Efficiency Programme
Example of savings potential
• Turnover £1 million• Profit (10%) £100,000
• Energy Cost (4%) £40,000• Savings potential (20%) £8,000
• Equivalent to 8% rise in profits• Turnover increase of £80,000
ENWORKS Resource Efficiency Programme
Other benefits
• Improved reliability – plant/service
• Better working environment
• Increased output
• Competitive advantage
ENWORKS Resource Efficiency Programme
Energy management
1. Make someone responsible
2. Establish the facts
3. Compare your performance
4. Plan & Organise
5. Pay less for your energy
6. Use less energy
7. Control & Monitor
ENWORKS Resource Efficiency Programme
Or
• Consider:• Management• Monitoring• Actions• People
ENWORKS Resource Efficiency Programme
Management - Buy it cheaper
• Energy contract negotiation
• Simple tendering process
• Make sure you are familiar with components of energy bills• beware of estimates • electricity maximum demand
• Checking the small print (e.g. notice required)
ENWORKS Resource Efficiency Programme
Monitoring - Where is it being used?
• 3 main areas:• Process – machines, tools, process
heating, furnaces• Services – compressed air, steam,
hot/cold water• Building Services – space heating,
ventilation, lighting
ENWORKS Resource Efficiency Programme
Monitoring - Where is it being used?
• Produce an energy map
• Identify the five biggest energy consumers in your company
• Use pareto rule
80% of energy used by 20% of process
ENWORKS Resource Efficiency Programme
What to monitor?
• Electricity• Day Units• Night Units• Availability & Maximum Demand• Power factor
• Gas• Units• Degree Days
ENWORKS Resource Efficiency Programme
Monitoring - Day and night units
0
10,000
20,000
30,000
40,000
Day Units (kWh) Night Units (kWh) Total Units (kWh)
ENWORKS Resource Efficiency Programme
Maximum Demand
• The peak instantaneous demand during a specific period (kW or kVA)
020
40
60
80
100
120140
7 9 11 13 15 17 19 21 23 1 3 5 Hours
kVA
Monitoring
ENWORKS Resource Efficiency Programme
Availability
• The reservation of an agreed capacity with your supply company (kVA)
• Should be set at approximately 10% above maximum demand
0
20
40
60
80
100
120
140
7 10 13 16 19 22 1 4 hours
kVA
Monitoring
ENWORKS Resource Efficiency Programme
Availability and maximum demand
0
100
200
300
400
Availability (kVA) Maximum Demand (kVA)
Cause of problem:Equipment failure
Additional cost due to equipment failure
ENWORKS Resource Efficiency Programme
(kVA)(kWh)
(kVArh)
BeerReal Beer
Froth
Power Factor & Reactive Power Charge
Monitoring
ENWORKS Resource Efficiency Programme
Power factor
0.5
0.6
0.7
0.8
0.9
1.0
Equipment Failure
ENWORKS Resource Efficiency Programme
Monitoring - Half-hourly Metering
• Available to above 100 kW Maximum Demand market • Approximately £1,000 per month
• Metering company take a reading every ½ hour
• Smaller consumers can hire portable metering equipment
ENWORKS Resource Efficiency Programme
0:30 1:00 1:30 2:00 2:30 3:00 3:30 4:00 4:30 5:00 5:3001/10/1999 1 1 1 1 1 1 1 1 1 1 102/10/1999 1 1 1 1 1 1 1 1 1 1 103/10/1999 1 1 1 1 1 1 1 1 1 1 104/10/1999 1 1 1 1 1 1 1 1 1 1 105/10/1999 2 2 2 2 2 2 2 2 2 2 206/10/1999 2 2 2 2 2 2 2 2 2 2 207/10/1999 2 2 1 2 1 2 2 2 2 1 208/10/1999 2 2 2 2 2 2 2 2 2 2 209/10/1999 1 1 1 1 1 1 1 1 1 1 110/10/1999 1 1 1 1 1 1 1 1 1 1 111/10/1999 1 1 1 1 1 1 1 1 1 1 112/10/1999 1 1 1 1 1 1 1 1 1 1 113/10/1999 2 2 2 2 2 2 2 2 2 2 214/10/1999 2 2 2 2 2 2 2 2 2 2 215/10/1999 1 2 1 2 2 1 2 1 1 1 116/10/1999 0 1 0 1 1 0 1 0 1 1 017/10/1999 1 1 0 1 0 1 1 1 1 1 018/10/1999 0 1 0 1 1 0 1 0 1 1 019/10/1999 2 2 2 2 2 2 2 2 2 2 220/10/1999 2 2 2 2 2 2 2 2 2 2 221/10/1999 2 2 2 2 2 2 2 2 2 2 222/10/1999 1 2 1 1 1 2 1 2 1 2 223/10/1999 0 0 0 0 0 0 0 0 0 0 024/10/1999 0 0 0 0 0 0 0 0 0 0 025/10/1999 0 0 0 0 0 0 0 0 0 0 026/10/1999 1 2 1 1 2 1 1 2 1 1 127/10/1999 2 2 2 2 2 2 2 2 2 2 2
Data received in spreadsheet form
ENWORKS Resource Efficiency Programme
1/2 hourly readings for 6 Months
0
50
100
150
200
250
DATE
KW
h
ENWORKS Resource Efficiency Programme
1/2 hourly consumption profile - monthly
0
50
100
150
200
250
September
KW
h
ENWORKS Resource Efficiency Programme
1/2 hourly electrical consumption profile - weekly
0
50
100
150
200
250
04/09/2000Monday
05/09/2000Tuesday
06/09/2000Wednesday
07/09/2000Thursday
08/09/2000Friday
09/09/2000Saturday
10/09/2000Sunday
DAY
KW
h
ENWORKS Resource Efficiency Programme
1/2 hourly consumption profile - daily
0
50
100
150
200
250
KW
h
ENWORKS Resource Efficiency Programme
How does consumption vary against production?
• Monitoring against time valuable• However, peaks and troughs can be
misleading
Weeks
KW
h e
lect
rici
ty t
o o
ven A
B
ENWORKS Resource Efficiency Programme
How does consumption vary against production?
Production figures
KW
h t
o O
ven
(B)
(C)
(A)
ENWORKS Resource Efficiency Programme
Energy Consumption -v's- Production
0
500
1000
1500
2000
2500
0 20 40 60 80
Production (tonnes)
Elec
trici
ty U
se k
Wh
Y = 22x + 789
C
m1
m2
ENWORKS Resource Efficiency Programme
Base load - Fixed costs
• C on the graph
• Start-up losses
• Operating losses such as compressed air leaks
• Equipment running despite absence of any load
• The use of any equipment that doesn’t add value to the product - ancillary equipment
ENWORKS Resource Efficiency Programme
Unit costs - Variable costs
• M on the graph
• Process Yield
• Off-spec, scrap or non-saleable product
• Product re-working
• Product finishing
ENWORKS Resource Efficiency Programme
Monitoring - Sub-metering
• Separate specific areas• Office• Production area
• Data loggers• Specific pieces of plant, machinery
ENWORKS Resource Efficiency Programme
MonitoringCompare performance - BenchmarkingBuilding Type Good Poor
Offices
Cellular
Open plan
Air-conditioned
(£/m2)
3.74
4.70
8.40
(£/m2)
6.47
7.79
14.92
Factories
General
Light
warehouse
(£/m2)
7.80
5.50
4.00
(£/m2)
10.60
9.20
5.60
ENWORKS Resource Efficiency Programme
Actions No & low cost solutions
• Energy walk-round• Procedures ignored?• Repairs or maintenance needed• Overheating• Lighting• Draughts• Regular maintenance/servicing
ENWORKS Resource Efficiency Programme
No & low cost solutionsElectric motors
• Often account for 60% of electricity costs
• Common problems• Oversized motors• Poor power factor/performance
• Common solutions• Motor audit – numbers, size• Maintenance• Buy high-efficiency
ENWORKS Resource Efficiency Programme
No & low cost solutions Compressed air
• 10 times more expensive than electricity • hole the size of pinprick in an air line can =£120
per year
• 30-40% compressed air leakage rate is common - 10-15% should be the target• Good housekeeping• Turn off when not needed• Leakage detection• Minimise
• Audit – see manual
ENWORKS Resource Efficiency Programme
No & low cost solutions Fuel use
• Regular servicing
• Monitor MPG / driver performance
• Route planning• software
• Conversion to cleaner fuels • Powershift
ENWORKS Resource Efficiency Programme
Actions - Equipment investment
• High efficiency motors• Variable speed drives• Energy efficient lighting• Building insulation• Financial assistance• Enhanced capital allowances• Loans• Capital grants
ENWORKS Resource Efficiency Programme
People - Myths and legends
• “Leaving the lights on is more economical than switching them off” • “Leaving equipment such as compressors,
machine tools and other motors on is more economical than switching them on and off all the time” • “Office equipment such as computers use
hardly any electricity”
ENWORKS Resource Efficiency Programme
People - Get them involved
• Measuring
• Monitoring
• Awareness raising
• Maintenance
• Planning
ENWORKS Resource Efficiency Programme
Case Study - Wild Manufacturing
• Presswork company – 180 employees• EMS driven – energy was key
cost/environmental impact• Formed committee• Measured• Set targets
• 10% utilities reduction in first year• Awareness raising campaigns
• “switch off, turn off, save it”
ENWORKS Resource Efficiency Programme
Case Study - Wild Manufacturing
• What they did• Focused on ‘common sense’
housekeeping issues• Check & repair procedures for
compressors• Fitted light sensors• Sealed gaps around windows & doors• Kept traffic doors shut as much as possible• Publicised consumption data to staff
ENWORKS Resource Efficiency Programme
Case Study - Wild Manufacturing
• What they achieved (first year)• Reduced electricity costs by 13%• Reduced gas costs by 7%• Vastly improved staff awareness
• SAVINGS IN £££££££
ENWORKS Resource Efficiency Programme
Energy support
• Action Energy• Helpline – 0800 58 57 94• Publications• Interest Free Loans• On-site surveys
• Must have consumption £50,000+• www.actionenergy.org.uk
The European Regional Development Fund (ERDF)
Workshop 1
Energy Auditing
The European Regional Development Fund (ERDF)
Workshop 2
Understanding Your Energy Bills
The European Regional Development Fund (ERDF)
Workshop 3
Energy Efficiency Action Plan
The European Regional Development Fund (ERDF)
Module 2 - Packaging
ENWORKS Resource Efficiency Programme
Why focus on packaging?
• Legislation
• It is expensive• As a raw material• To dispose of
• Offers a lot of opportunity
ENWORKS Resource Efficiency Programme
Learning objectives
• To help you save money by optimising packaging
• To understand the legal obligations for packaging use and waste
• To provide ideas to reduce, re-use and recycle packaging materials
ENWORKS Resource Efficiency Programme
What is packaging?
• “All products made of any materials of any nature to be used for the containment, protection, handling, delivery and presentation of any goods” The Producer Responsibility Obligations (Packaging Waste) Regulations, 1997
ENWORKS Resource Efficiency Programme
What is packaging?
Packaging Material
Stretch Wrap Pins Shrink Wrap Cards
Sacks Air bags Bottles Pallets Banding
Slip sheets Edge protectors Bubble Wrap Dividers Cores Padding Drums Bedding Trays
Cartons Crates Crumpled paper Containers
Polystyrene chips Adhesive tape Strapping
ENWORKS Resource Efficiency Programme
Why do we use packaging?
5 major reasons
• To protect the product• To prevent contents escaping• To be compatible with
storage/handling systems• To identify products• To market
ENWORKS Resource Efficiency Programme
Packaging management
• Packaging Management can be defined as:
“ a systematic approach that allows the most efficient use of packaging and packaging materials in order to reduce costs and material wastage without compromising product protection, handling and storage”
ENWORKS Resource Efficiency Programme
Why manage? - Legislation
• 2 Specific Regulations in UK:• Producer Responsibility Obligations
(Packaging Waste) Regulations• Packaging Essential Requirements
• Landfill Tax
• Duty of Care
ENWORKS Resource Efficiency Programme
Why manage? - Other benefits
• Supply-chain pressures• good communication
• Improved company image
• Improved environmental performance
• Can demonstrate good environmental management system
ENWORKS Resource Efficiency Programme
TRUE COST OF
PACKAGING
Packaging materials loss
Treatment and disposal
Storage
Transport Materials handling
Monitoring and analysis
Why manage?
Compliance
Purchase of packaging
ENWORKS Resource Efficiency Programme
Minimise your packaging
• Eliminate – prevention rather than cure
• Reduce
• Re-use
• Recycle
• Disposal as last resort
• ALWAYS CONSIDERING ‘FIT FOR PURPOSE’
ENWORKS Resource Efficiency Programme
Eliminate
• Is it really needed?
• Reduces all costs
• Any company examples?
ENWORKS Resource Efficiency Programme
Reduce at sourcePackaging design & optimisation
• Match the level of packaging to the level of protection required
• Should be part of the overall design process and integral to product design
ENWORKS Resource Efficiency Programme
Reduce at sourcePackaging design & optimisation
• Minor changes in packaging design• Size & shape of containers• Type and grade of material used
• Alternative on-site handling and distribution• Bulk delivery• switching from drums to returnable IBC’s
can save raw materials and landfill costs
ENWORKS Resource Efficiency Programme
Reduce at sourceQuestion the norm
• Plastics• Can a thinner material be used without
compromising product protection?• Can a different material be used? – checking
puncture resistance & stretch capacity• Pallets• Are there any alternatives? E.g. slip-sheets• Are they of optimum design? Lightweight for
one-trip; robust for ‘closed-loop’ systems
ENWORKS Resource Efficiency Programme
Case Study
• Armacell UK
• Customer & employee consultation
• Redesign
• Grant assistance
ENWORKS Resource Efficiency Programme
Expected benefits
• Reduced waste to landfill (own & customers)• Cost savings of £140,000 over next 5 years
• Elimination of single-trip packaging• Introduction of durable multi-trip packaging• Reduced energy consumption• Reduction in associated transport (Europe-wide)
and packaging use.• Reduction of storage space and associated
lighting
ENWORKS Resource Efficiency Programme
Reusing packaging
• Assess the potential to re-use existing packaging• Can it be multipurpose?• Can it be re-used on site or by another
company?• Can better handling help?
ENWORKS Resource Efficiency Programme
Reusing packaging
• ‘Closed Loop’ systems• Most economical• Reduce environmental impact• Effective for short transportation distances
ENWORKS Resource Efficiency Programme
Reuse - Design & purchase
• Simple, standard containers equal flexibility of use
• Design containers to stack or collapse where practicable
• Incorporate labelling and identification features
ENWORKS Resource Efficiency Programme
Recycling packagingDesign options
• Use recycled/recyclable material wherever practicable & fit for purpose
• Use a single material where possible – mixing creates difficulties
• Can labels be made of the same material as the rest of the packaging?
• Mark packaging to enable easy segregation
ENWORKS Resource Efficiency Programme
We don’t produce much!
• Or:• Our waste management contractor won’t
recycle our packaging waste• We operate in a remote area
• Try teaming up with other companies in the area• Communal skips• Collection rounds• Waste Brokerage
ENWORKS Resource Efficiency Programme
Further assistance
• Envirowise Publications
www.envirowise.gov.uk
• Design Track visit• Available to Small to Medium-Sized
companies (SMEs)
The European Regional Development Fund (ERDF)
Workshop 4
Packaging Design
The European Regional Development Fund (ERDF)
Workshop 5
Reducing Packaging Waste
The European Regional Development Fund (ERDF)
Workshop 6
Packaging Efficiency Action Plan
The European Regional Development Fund (ERDF)
Module 3 - Waste Management
ENWORKS Resource Efficiency Programme
Learning objectives
• Reinforce the importance of moving up the waste hierarchy
• Identify techniques to:• manage waste• improve waste disposal options
ENWORKS Resource Efficiency Programme
Why manage waste?
• It’s Expensive
• Legislation
• Political Agenda
• Social Agenda
ENWORKS Resource Efficiency Programme
Legislation
• Environmental Protection Act 1990• Duty of Care Regulations• Documentation
• Special Waste Regulations 1996 (amended)
• Segregation• Consignment notes• Notify Environment Agency
ENWORKS Resource Efficiency Programme
Legislation
• Waste Management Licensing Regulations 1994• Contractors• Activities performed on wastes
ENWORKS Resource Efficiency Programme
Legislation
• Landfill Tax (Finance Act 1996)
• Producer Responsibility Obligations (Packaging Waste) Regulations 1997
• Landfill Directive
• WEEE Directive
ENWORKS Resource Efficiency Programme
The Waste Hierarchy
Reduce
Re-use
Recycle
Eliminate
Treat to dispose
DisposalHow do I reach the top?
ENWORKS Resource Efficiency Programme
Eliminate / replace
• Elimination of waste is the best option• Reduce resource use• Reduce pollution• Use fewer resources
• Ask the following questions:• Why is there waste at all?• Does the waste really have to be produced?• Can some of it be eliminated?
ENWORKS Resource Efficiency Programme
Eliminate / replaceCase Study – Spray painting
• Masking tape was purchased at £15 / roll
• After review, this was found to be over specified for many applications
• Cheaper tape is now used, costing £6 / roll
• Savings are estimated at £4,500 pa
ENWORKS Resource Efficiency Programme
Reduce
• Can’t be eliminated, how do we reduce it?• Why is there so much of this waste?• Where does it come from?• What steps can we take to reduce it?
ENWORKS Resource Efficiency Programme
ReduceCase Study - Armacell
• Set a target to reduce solid waste to landfill • Reduced from 300 tonnes (in 2000) to 70
tonnes (in 2003).• Despite increase in output over last 2 yrs
• Achieved by finding an alternative use for scrap• Made crumb into a new acoustic product
ENWORKS Resource Efficiency Programme
Reuse
• Reusing waste within a process removes all waste disposal costs
• However, processing materials several times is expensive
ENWORKS Resource Efficiency Programme
Reuse Case Study - Armacall
• Target to reduce wood sent for recycling by 25%
• Implemented programme of pallet repair• Cost £3685 to set up• Reduced wood to recycling by 45% to
15 tonnes• Savings worth £9350
ENWORKS Resource Efficiency Programme
Reuse
• WRAP: Waste Resources Action Programme
• To develop markets and infrastructure
www.wrap.org.uk
ENWORKS Resource Efficiency Programme
ReuseWaste brokerage
• One persons waste is another persons raw material
• ENWORKS offer a waste brokerage service• Free• Confidential
• Websites: www.wasteworks.org.uk
ENWORKS Resource Efficiency Programme
Waste brokerageCase study
• Waste incontinent pads produced by one company
• Off-spec being sent to landfill
• Used by another company as spillage kits• Saved 2 tonnes of waste from landfill
ENWORKS Resource Efficiency Programme
Recover / recycle
• Better financially and for environment• Recycling wastes avoids payment of
landfill costs• Prices fluctuate considerably due to
instability of recycling markets• Includes many ‘hidden’ costs• Includes composting, recycling and
recovering energy from waste
ENWORKS Resource Efficiency Programme
Treatment
• Treating waste prior to disposal could include compaction, baling or effluent treatment
• Over £50/week on waste
• Incurs additional processing costs, however, may reduce disposal costs
ENWORKS Resource Efficiency Programme
Disposal
• Worst option• For the environment • Usually most expensive option• Needs careful management
• Remember true cost of waste is often 10 – 20 times that of disposal
ENWORKS Resource Efficiency Programme
Managing waste Skip management
• Benefits of management• Reduce costs• Reduce risks• Reduce waste
ENWORKS Resource Efficiency Programme
Skips
• Costs• Legislation• Skip hire/Transport/Disposal• Raw materials• Storage• Containment• Labour• Segregation• Security• Training
ENWORKS Resource Efficiency Programme
Collect data
• Baseline information• What skips do you have?• Who is your contractor?• Where does the waste go?• Do you have the documentation?• Who is involved?• What are the risks?
ENWORKS Resource Efficiency Programme
Consider your options
• Look again at the waste hierarchy
• Consider the best disposal option for each waste stream
• Always be aware of legislation
ENWORKS Resource Efficiency Programme
Audit
Audit waste on site:• What are the individual waste streams? • What are the quantities?• Are wastes segregated?• What is the legislation that applies to you?• How much does this cost?• Disposal• ‘True cost’
ENWORKS Resource Efficiency Programme
Audit
• Who is responsible for waste management?
• What training have they had?
• What mechanisms are in place to ensure that wastes are segregated and disposed of correctly?
ENWORKS Resource Efficiency Programme
Monitoring
• Monitor system to ensure it is working
• Collect accurate data on volumes for target setting
• Review system regularly
ENWORKS Resource Efficiency Programme
Waste contracts
• Regularly negotiate your contract• Frequency of lifts• Capacity• Type of Skip
- size- security- compatibility
• Are they licensed?
ENWORKS Resource Efficiency Programme
Summary
• A good waste management system:• Identifies opportunities • Can reduce legal risks and
environmental impact• Save money
The European Regional Development Fund (ERDF)
Workshop 7
Waste Management
The European Regional Development Fund (ERDF)
Workshop 8
Waste Management Action Plan
The European Regional Development Fund (ERDF)
Module 4 - Water
ENWORKS Resource Efficiency Programme
Learning objectives
• To understand water costs
• To gain an understanding of water management
• Identify options to reduce water costs
ENWORKS Resource Efficiency Programme
The Water Cycle
Why focus on water?
• It can be a significant cost
• It may be an underestimated cost
• There are cost savings to be made
• Costs are increasing
• Legislation is forcing us – discharge consent
• Considerable fines for breaching this legislation
Water management
• Similar approach to energy management
• Monitoring – over time and against production
• Common areas of savings
Water billing and purchasing
• No possibility to negotiate water supply
• Check bills (meter number, meter readings, estimates, maths…)
• Key water cost components:• Water consumption• Sewerage – waste water disposal• Sewerage – surface water• Trade effluents
Are you charged correctly?
• Water not returned to sewers• Water used in production/evaporated• Grassed area• Local streams
• Rateable value• Size of meter • Fixed rate charges based on meter • Reduce size of meter
ENWORKS Resource Efficiency Programme
Trade effluents
• Based on a formula (Mogden)
• Ensure correct charging formula is used
• Ensure correct volumes are used
• Ensure representative samples are taken
Where is water used?
• Focus on key areas/costs
e.g. Trade effluents or domestic use
• Map water use/disposal on site
e.g. Water used as part of production, ancillary activities (cooling system)
ENWORKS Resource Efficiency Programme
Where do businesses use water?
ENWORKS Resource Efficiency Programme
Water measuring
• Calculate usage for un-metered processes• Toilets• Urinals
• Bucket and stop watch
• Flow meter
COST £££££££
ENWORKS Resource Efficiency Programme
Water balance
• Simple premise that what goes in must come out somewhere
ENWORKS Resource Efficiency Programme
Case Study JW Lees & Co (Brewers) Ltd
• Water audit and monitoring and found leaks
• Invested £400
• Immediate saving of £13,000 per annum
Water monitoring
• Monitor water costs/volume over time
• Monitor against production
Trade effluents• Contamination levels• Less contaminated effluents will be
cheaper to dispose of• Possibilities to re-use trade effluents
• Trade effluents treatments• Various technologies – filtration,
sedimentation, centrifugation• Beware of treatment costs and deposit
disposal costs• Envirowise publications
Trade effluent monitoring
0500
1,0001,500
2,0002,5003,000
3,5004,000
4,5005,000
Efflu
ent C
ost (
£)
Ct= Total Cost (£)COD Charge (£)Suspended solids charge (£)
ENWORKS Resource Efficiency Programme
Over-use / unnecessary use
• Working practices• Tap left running• Sinks filled unnecessarily
• Leaks• One drip per sec wastes 4 litres per day
• Over-flows
ENWORKS Resource Efficiency Programme
One drop/second4.8 m3/year£3 - £7/year
Drops breaking to a stream31 m3/year£18 - £48/year
3 mm stream336 m3/year£193 - £519/year
Water losses from a tap
ENWORKS Resource Efficiency Programme
Water controls
• Taps• Automatic shut-off or spray head taps use
about 80% less water than traditional column taps
• Level sensors (to avoid over-flows)• Pipe/tap restrictors• Hippos• Trigger guns for wash down hoses
ENWORKS Resource Efficiency Programme
Counter current rinsing
• If water is a big part of your process where washing is vital
Rinse CRinse D Rinse ARinse B
Work
Fresh water
drain
Water recycling
• Could you recycle water from cooling or rinsing processes?
• Could you condensate steam to re-use water?
• Could you use waste water or rain water as part of your processes?
ENWORKS Resource Efficiency Programme
Grey water reuse
• Water from a rinsing process
• Vehicle washing
• Kitchens
ENWORKS Resource Efficiency Programme
Water management summary
• Track water to control costs and legal risks
• Simple measures can lead to quick savings
ENWORKS Resource Efficiency Programme
Envirowise
• Free half-day FastTrack visits• smaller companies (< 250 employees)
• Free publications‘Tracking Water Use to Cut Costs’
0800 585794www.envirowise.gov.uk
The European Regional Development Fund (ERDF)
Workshop 9
Assessing Water Use
The European Regional Development Fund (ERDF)
Workshop 10
Water Efficiency Action Plan
The European Regional Development Fund (ERDF)
Module 5 – Emissions to Air
ENWORKS Resource Efficiency Programme
Learning objectives
• To understand air pollution and it’s causes• To understand the legislation that
controls emissions to air • To understand the environmental and
business benefits of effective emissions management
ENWORKS Resource Efficiency Programme
Air emissions
• Economic case – reduce inefficiencies• Loss of raw materials e.g. solvents• Poor management
• Visible – public perception• Controlled by legislation• Licenses
• Health and safety
ENWORKS Resource Efficiency Programme
Emissions to atmosphere
• Gases• Carbon monoxide• Solvents
• Dust• Burning fossil fuels• Construction
• Smoke• Cars• Power stations• Furnaces
ENWORKS Resource Efficiency Programme
Global warming• Average increase in global temperatures• Natural mechanism - the Greenhouse Effect
• Gases form insulating blanket around Earth (carbon dioxide, methane, CFCs)
• Concentration of gases increased by human activity:• Burning fossil fuels• Vehicles• Waste – landfill• Intensive agricultural practices
ENWORKS Resource Efficiency Programme
Kyoto 1998
• International agreement• Legally binding targets to reduce GHG
emissions
• 20% reduction in CO2 emissions by 2010
• Climate Change Levy introduced in April 2001• Increase energy bills by 10 – 15 %
ENWORKS Resource Efficiency Programme
Ozone depletion
• Man-made chemicals entering the atmosphere – CFCs, halons
• React in the atmosphere and damage the ozone layer
• Montreal Protocol 1987 restricted production of ozone depleting chemicals
• Can take years for gases to have an affect
ENWORKS Resource Efficiency Programme
Acid rain
• Acid gases – sulphur dioxide and nitrogen dioxide• Burning fossil fuels • Motor vehicles – exhaust emissions
ENWORKS Resource Efficiency Programme
Smog
• Smog refers to a mixture of pollutants that form a haze over cities, particularly in summertime
• Main source of pollutants is motor vehicles
• Ozone that is formed can attack eyes, nose, throat and lungs – particularly asthma sufferers
• Weather reports now include air quality
ENWORKS Resource Efficiency Programme
Control of emissions
• Legislation• IPC and IPPC• Clean Air Act 1993
• Climate Change Levy
• National Air Quality Strategy
• Solvent Emissions Regulations 2004
ENWORKS Resource Efficiency Programme
Controls
• Integrated Pollution Prevention and Control (IPPC)
• Adopted in 1996, and will replace IPC
• Both aim to prevent or reduce emissions to air, water and land
• Includes measures to reduce waste and increase energy efficiency
• Requires investment in abatement equipment
ENWORKS Resource Efficiency Programme
Controls
• Best Available Technology Not Entailing Excessive Cost (BATNEEC)• IPC
• Best Available Technology (BAT)• IPPC
ENWORKS Resource Efficiency Programme
Managing emissions
• Managing the process• Energy efficiency• Raw materials e.g. solvents
• Managing transport
ENWORKS Resource Efficiency Programme
Emissions management Monitoring
• Provide information for regulators• Identify opportunities:• Reduce consumption of raw materials • Reduce emissions
• Demonstrate continuous improvement• Fulfil health and safety requirements• Improve working conditions
ENWORKS Resource Efficiency Programme
Monitoring techniques
• Based on material balancing • What goes in must come out
• Measurements taken:• Intermittently - sampling • Continuously - probe
ENWORKS Resource Efficiency Programme
Solvent management
• Solvents / VOCs
• Organic compounds - used as:• Dispersants• Cleaning agents• Viscosity modifiers• Chemical reactants
ENWORKS Resource Efficiency Programme
Common solvents
• Hydrocarbons (hexane, toluene, xylene)
• Alcohols (ethanol, isopropanol)
• Ketones (MEK, MIBK)
ENWORKS Resource Efficiency Programme
Why manage?Cost savings & public relations
• Solvents are expensive
• £500 - £2000 / tonne
• Demonstrates good overall management of risks and performance
ENWORKS Resource Efficiency Programme
Why manage? Environmental & health reasons
• Harmful to health (carcinogens, irritants)
• Contribute to global warming
• Can create low-level ozone (respiratory problems, irritation to ENT)
ENWORKS Resource Efficiency Programme
Why manage? Legislation
• PPC
• IPPC
• Solvent Emissions Regulations 2004
ENWORKS Resource Efficiency Programme
How to manage Step 1 – Consumption & emissions
• Gain Commitment
• Estimate:• Annual solvent cost• Cost of this consumption
ENWORKS Resource Efficiency Programme
Step 2 – Solvent flows
ENWORKS Resource Efficiency Programme
Step 3 – Calculate emissions Initial assessment
• Look at :• Inputs (purchases, recovered solvents)
• Outputs (solvent in product, water, waste, etc.)
• Stock Changes
• Emissions = I – O – S
ENWORKS Resource Efficiency Programme
Step 4 – Calculate costs
• Include:• Purchase costs• Costs of disposal• Costs of on-site recovery• Costs of operating LEV / abatement• Costs of process authorisation
ENWORKS Resource Efficiency Programme
Step 5 – Solvent management team
• Solvent Manager• Responsibilities• Accountability• Resources• Support
• Solvent management file
ENWORKS Resource Efficiency Programme
Step 6 – Implement savings initiatives
• Training / motivation
• Delivery (Bulk, IBCs)
• Storage (above-ground tanks)
• Distribution
• Processing (keep lids on, housekeeping)
• Cleaning (use clean solvent only for last wash)
• Recovery / Reuse
ENWORKS Resource Efficiency Programme
Benefits
• Reduced operating costs• Solvent purchases• Disposal costs• Compliance costs
• Increased efficiency / quality
• Improved image
ENWORKS Resource Efficiency Programme
Fleet management
• Road transport accounts for over 90% of passenger travel in UK• 58% of car journeys are under 5 miles and
25% are less than 2 miles• In heavy traffic jams, air quality can be 3
times worse inside the car than out• Average distances cycled & walked have
fallen by ¼ over past 20 years
ENWORKS Resource Efficiency Programme
Harmful effects
• Contributes to Key Issues:• Air Pollution – 70% of all carbon monoxide emissions relate
to cars• Asthma• Exhaust gases
• Climate change• Acid rain
• Resource Depletion – fuel & production• Noise Pollution• Road Building – pressure on countryside
ENWORKS Resource Efficiency Programme
Business & transport• What for?
• Staff• Distribution• Deliveries• Business travel
• People travelling to work account for one-fifth of all road traffic• 70% of journeys to work are by car• Traffic delays cost the UK £15billion / year• Car traffic set to increase by 22% by 2010 = 26
million registered cars
ENWORKS Resource Efficiency Programme
What's your position?
• How many vehicles?
• How much business related mileage?
• How much fuel consumption
• What is the potential for cost savings?
ENWORKS Resource Efficiency Programme
Fleet managementVehicle selection
• For each vehicle?
• What size/spec is really needed?
• What fuel type is the best option?• Petrol / diesel• LPG• Electric• Hybrid
ENWORKS Resource Efficiency Programme
Fleet managementVehicle selection
• Which model is best (for efficiency and CO2 emissions)? • Vauxhall Corsa 1.2 LPG• Suzuki Alto/Swift 1.1• Vauxhall Astra 1.6 LPG• Honda Civic IMA Hybrid• Vauxhall Corsa 1.0
ENWORKS Resource Efficiency Programme
Fleet managementDriver training
• Using best methods can reduce costs & environmental benefits:• Smooth driving (up to 10% reduction in fuel
consumption)• Correct gear selection (up to 25% saving)• Check tyre pressure regularly (under-inflated by
2ps can reduce efficiency by at least 1%)• Plan your journeys (20% of driving from being lost)
ENWORKS Resource Efficiency Programme
Fleet managementEncourage other methods
• Car sharing
• Public transport
• Cycling / Walking (Healthy Workplace?)
ENWORKS Resource Efficiency Programme
Fleet managementMonitoring & planning
• Monitor mileage and fuel use
• Identify:• Inefficient vehicles• Inefficient drivers• Fraud
ENWORKS Resource Efficiency Programme
Fleet managementMonitoring & planning
• Planning business trips• Is telecommunication an alternative?• Choose off-peak travel• Choose venues that will reduce travel
times for all• Can you car share?
ENWORKS Resource Efficiency Programme
Grants and assistance
• Powershift
• New vehicle technology fund
• Motorvate• www.transportenergy.org.uk
• CleanUp• www.cleanup.org.uk
ENWORKS Resource Efficiency Programme
More information• ENWORKS – 0800 032 0222
• Envirowise - 0800 585 794• www.envirowise.gov.uk• GG 203 Monitoring VOC emissions: Choosing the best options• GG 71 Cost-effective reduction of fugitive solvent emissions• GPG 218 Fuel-efficiency fleet management• GPG 314 Travel plan networks
The European Regional Development Fund (ERDF)
Workshop 11
Savings in Solvents
The European Regional Development Fund (ERDF)
Workshop 12
Air Emissions Efficiency Action Plan
The European Regional Development Fund (ERDF)
Module 6 - Materials
ENWORKS Resource Efficiency Programme
Learning objectives
• Understand the impact of purchasing on resource efficiency
• Be familiar with the general principles of life cycle assessment
• Understand the benefits of cleaner design and supply chain management
ENWORKS Resource Efficiency Programme
Why purchasing?
• Legislative pressures• Producer Responsibility (Packaging Waste)
Regulations• Packaging (Essential Requirements)• WEEE and ELV
• Stakeholder pressure• Supply chain pressure• European policy • Sustainable development
ENWORKS Resource Efficiency Programme
Business benefits
• Reduce waste
• Enhance company image
• Secure supply of materials and services
• Cost saving and added value
• Create markets for new products and services
ENWORKS Resource Efficiency Programme
Stages in purchasing
ENWORKS Resource Efficiency Programme
Practical steps
• Create an environmental purchasing policy• Included in environmental policy or as stand
alone policy
• Identify alternatives• EMS (ISO 14001, BS 8555)• Labelling and information – Eco-labels
ENWORKS Resource Efficiency Programme
What is life cycle assessment
• Examines material, energy and waste flows of a product over its entire life-cycle
• Identifies areas of highest impact, thus allowing redesign activities to be prioritised
ENWORKS Resource Efficiency Programme
ENWORKS Resource Efficiency Programme
Stages of life cycle assessment
• Set your goal and scope• Inventory analysis• Gather data on the environmental burdens of a
product
• Impact assessment• Group environmental burdens e.g. greenhouse
gases
• Interpretation• Identify changes to product or production process
ENWORKS Resource Efficiency Programme
Benefits of LCA
Life-Cycle Stage Consideration
Raw Material • Use less materials
• Use materials with less impact
Manufacture • Use fewer resources
• Produce less waste / pollution
Distribution • Reduce the impact of distribution
Use • Use fewer resources
• Cause less pollution
• Optimise functionality and service
End-of-Life • Make re-use and recycling easier
• Reduce the environmental impact of disposal
ENWORKS Resource Efficiency Programme
Benefits of LCA
• Identification of environmental impacts – including waste
• Increased efficiency of use of resources• Raw materials • Energy
• Improved quality
• Information to back marketing claims
ENWORKS Resource Efficiency Programme
Life cycle assessment
• Conducting an LCA can demonstrate increased environmental awareness
• Brings business benefits
• LCA can be complex and time-consuming
• New tools and methods help to simplify this
• LCA is a platform for innovation
• Increased competitiveness
ENWORKS Resource Efficiency Programme
Case StudyAvad Contemporary Furniture
• Produces high-quality, bespoke furniture
• Uses reclaimed or sustainably sourced hardwoods
• Developed new jointing and production techniques, some of which use no glue or metal
ENWORKS Resource Efficiency Programme
• Life-cycle assessment (LCA) shows that, in the example studied, the nearest comparable techniques have almost twice the environmental impact
• Identified local sustainable timber source
• Continued research into sustainable design
• Planning marketing programme to promote cleaner products
Case StudyAvad Contemporary Furniture
ENWORKS Resource Efficiency Programme
Barriers and solutions to LCA
• Time and resources• Simplify boundaries• Use checklists
• Lack of expertise• Look at case studies, industry examples• Use external agencies
• Lack of data• Use the internet• Generic LCA data from Envirowise, Environment Agency
ENWORKS Resource Efficiency Programme
Improvements from LCA
• Change input materials• Using water based products
• Technological changes• Improving process control• Redesigning process to enable heat recovery• Improving waste segregation
• Good operating practices• Preventing unnecessary releases• Reusing materials
• Product changes
ENWORKS Resource Efficiency Programme
Product changes Cleaner product design
• 93% of production materials do not end up in saleable products
• 80% of products are discarded after a single use
• 99% of materials used are discarded in the first six weeks
ENWORKS Resource Efficiency Programme
What is clean product design?
Cleaner design is the design of a product to minimise its environmental impacts over its entire lifetime and to meet customer requirements
ENWORKS Resource Efficiency Programme
Benefits of cleaner design
• Lower production costs
• Improved product functionality
• Increased market share
• Improved environmental performance
• Improved customer relationships
• Compliance with legislation
• Easy disassembly for recycling
• Longer product design life (future proof)
ENWORKS Resource Efficiency Programme
Case Study Varian Medical Systems UK Ltd
• Manufactures sophisticated x-ray equipment for simulating radiotherapy treatment
• Identified three drivers for cleaner design• Maintaining competitive advantage
• Forthcoming legislation
• Corporate policy
ENWORKS Resource Efficiency Programme
Main benefits:• Cost savings of £162 000/year achieved at a cost of
£24 620
• 65% reduction in number of components used
• 29% reduction in number of fasteners
• 27% reduction in assembly time
• Elimination of glass reinforced plastic (GRP)
• Switch to water-based paints
Case Study Varian Medical Systems UK Ltd
ENWORKS Resource Efficiency Programme
ENWORKS Resource Efficiency Programme
Research the product
• Consider the product’s life-cycle
• Examine the materials used in the product
• How is the product manufactured?
• How is the product distributed?
• How is the product used?
• What happens at the end of the product’s life?
• Talk to your suppliers and customers
ENWORKS Resource Efficiency Programme
Consider the life cycle
• Life-cycle assessment• Aims to identify environmental impacts arising
throughout the product’s whole life
• Life-cycle thinking• Generic LCA information
• Use cleaner design checklist
ENWORKS Resource Efficiency Programme
Examine the materials
• Create a list of all the materials used
• Look at the environmental impacts of these materials
• Identify alternatives• Use fewer materials • Only use materials that can be recycled• Use materials containing recyclates• Obtain from more sustainable sources• Talk to suppliers/customers
ENWORKS Resource Efficiency Programme
Product manufacture
• Is the process energy intensive?
• Does it produce a lot of waste?
• What other resources are used? • Water
• Can resource use be reduced?
ENWORKS Resource Efficiency Programme
Product distribution
• What type of packaging is used?
• Could less packaging be used?
• Could re-usable packaging be used?
• How is the product stored before dispatch?
• How far are the products transported?
ENWORKS Resource Efficiency Programme
Product use
• Talk to consumers to find out if they have developed ‘product habits’
• Do customers feel that any components or functions are unnecessary?
ENWORKS Resource Efficiency Programme
End of product life
• Does the product typically go to landfill?
• Could the recycling potential be increased?• Material selection
• Stamping and labelling
• Can modules or parts be re-used?
• Service potential
ENWORKS Resource Efficiency Programme
Disassembly
Design priorities
Redesign
Feedback
ENWORKS Resource Efficiency Programme
Talk to suppliers and customers Supply chain management
• Talk to suppliers and customers • About clean design• Specification of materials• Specification of products
• Ask them to join the design team• Helps to maintain business relationships• Can share information/benefits
• Can they suggest alternatives/ideas?
ENWORKS Resource Efficiency Programme
BenefitsSupply chain management
• Greater control of resource flows• Raw materials• Packaging
• Reduced costs• Quicker transfer times• Fewer quality failures• Solidified business links• Increased awareness throughout supply chain• Investigating product delivery methods
ENWORKS Resource Efficiency Programme
Environmental management
• Environmental purchasing
• Life-cycle assessment
• Resource efficiency
• Clean product design
• All fit into an EMS structure• BS 8555• ISO 14001
ENWORKS Resource Efficiency Programme
Further information
Envirowise 0800 585 794www.envirowise.gov.uk
PublicationsDesign Track visit
Enworks 0800 032 0222www.enworks.com
On-site supportCase studies
The European Regional Development Fund (ERDF)
Workshop 13
Clean Product Design
The European Regional Development Fund (ERDF)
Workshop 14
Material Efficiency Action Plan
The European Regional Development Fund (ERDF)
Resource Efficiency Training
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