Transcript Slide 1

Case study
“Implementation of EMAS in the Ceramic industry”
Case study:
Implementation of EMAS in the
Ceramic industry
Eng. Marisa Almeida - CTCV
CTCV - Coimbra
Fevereiro.2005
ETIV - EMAS Technical Implementation and Verification1
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Case study
“Implementation of EMAS in the Ceramic industry”
Issues:
1. Structure of the ceramic study-case
•
•
•
•
Ceramic process
Development of an EMS according to EMAS II
Enviromental improvement - photos
Main difficulties - photos
2. Training material
3. ETIV Main difficulties
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Case study
“Implementation of EMAS in the Ceramic industry”
Description of
ceramic location
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
1. Study case structure:
•
Part 1 –
•
•
•
Description of the company:
•
Maronagrés – ceramic tiles company – certified by
ISO9001:2000
•
Sanindusa 2 – Sanitaryware company;
Brief summary of the case study;
Driving forces and Benefits of EMAS
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
1. Study case structure:
•
Part 2 – Case studies: PDCA MODEL: Plan- DoCheck-Act
Integrated system - process approach
PLAN
 Collection of data on the organisation (design information,
environmental information, raw material/production information,
economic and other);
 Environmental Review Diagnostic;
 Environmental policy (A.2);
 Significant environmental aspects (A.3.1);
 Legal and other requirements (A.3.2);
 Objectives and targets (A.3.3);
 Environmental management program (A.3.4);
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
1. Study case structure:
•
Part 2 – Case studies:
Implementation and operation (Do):
 Definition of structure and responsibility and provide resources (see A.4.1);
 Training, awareness and competence (see A.4.2);;
 Establish internal and external communication (see A.4.3);
 Create and maintain EMS documents (see A.4.4);
 Documentation control (see A.4.5);
 Establish and maintain operational control (see A.4.6);
 Emergency preparedness and response (see A.4.7).
Checking and corrective action (Check):
 Monitoring and measurement (see A.5.1);
 Non-conformance and corrective and preventive actions (see 4.5.2);
 Manage Records (see 4.5.3);
 Conduct periodic EMS audits (see A.5.4).
Management Review (Act):
 conduct Management review (see A.6);
 identify areas for improvement;
 environmental declaration;
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
1. Study case structure:
•
Part 2 – Case studies:
ISSUES TO BE ADDRESSED BY ORGANISATIONS IMPLEMENTING EMAS
 Legal compliance
 Performance
 External communication and relations
 Employee involvement

Part 3 – Evaluation and conclusions
 Fundamental difficulties found;
 Experience collected by the company during EMAS implementation;
 Environmental improvements achieved (results, benefits);
 Photos of the environmental achievements of the Company;
 Conclusions
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
2. Ceramic process description
Ceramic Material Production
Processed material
Body preparation
Moulds Preparation
Forming/shaping (moulding
or pressing)
Drying
Glaze Preparation
Glazing -glaze application
Firing
Product finishing
Sorting, Packaging and
storage
auxiliar phases
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Case study
“Implementation of EMAS in the Ceramic industry”
Packing Materials
Moulds
Colouring
Deflocculant
Raw Materials
Glazes and Paints
Body Preparation
and atomization
2. Maronagrés ceramic
process
Granulation
Pressing
Drying
Decoration
Firing
Inputs
Sorting and
Packaking
Water
Electricity Energy
Thermal Energy
Control of the
quality
Outputs
Solid Waste
Liquid Effluent
Fugitive Emissions
Storage
Gaseous Emissions
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Casting Slip
SW
E
Forming
WW
W
W
2. Sanindusa 2
ceramic process
M
SW
Finishing
(1ª phase)
WW
FE
Pre-drying
FE
Finishing
(2ª phase)
WW
SW
Raw Material
Glaze
Preparation
W
Packing
Material
FE
GE
E
Drying
SW
Inputs
Glaze
preparation
W
Verification
and Finishing
(3ª phase)
SW
E
WW
SW
W
Glazing
WW
M
Components
and
accessories
E
Firing
(tunnel kiln)
Sorting
Energy - natural gas,
compressed air and GPL
W
Water
M
Material
Outputs
GE
SW
Solid Waste
GE
WW
Waste Water
FE
FE
Fugitive Emissions
GE
Gaseous Emissions
SW
M
Assembly of mechanisms and
components
E
SW
Packaking
DE
SW
Storage
FE
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Case study
“Implementation of EMAS in the Ceramic industry”
Implementation of EMS - EMAS
Environmental Review Diagnostic

data on the organization (location, production information, raw
materials and energy input);

environmental information:





Local conditions: geological, soil, atmospheric
Consumption data: raw material, water, energy
Emission data: emissions to air, emission to water, emission to land
– wastes, noise;
List of legislation and other requirement applicable to the
ceramic industry;
Planned activities (summary)
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
A.2 Environmental policy
Maronagrés quality and environmental policy states commitments to:







Continual improvement of product, process and services with a minimal
adverse environmental impact;
environmental legal requirements and other environmental requirements
to which the organization subscribes;
prevent pollution; efficient use of resources, avoid and minimized (and
valorization) the waste, gaseous emissions and noise control;
continual improvement through the implementation of the best available
technologies (BAT) adequate to its environmental impacts;
employees qualification and motivation;
documented, implemented, maintained and communicated , reviewed
the policy, objectives and other information regarding the Management
System (Q&E) to all employees and other interested parties;
involve interested parties like suppliers, clients and local community in the
Management System (quality and environment)
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A.2 Environmental policy:
* Integrated with quality
and heath and safety;
* focus on continual
improvement of product,
process and services
with a minimal adverse
environmental
* environmental legal
requirements and other
* best available
technologies (BAT)
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
3. Significant Environmental aspects and impacts
procedure
Environmental aspects
Wastewater
Energy
Water
Raw materials for ceramic body
Packaging materials
Auxiliary materials
Production
of
Ceramic
Materials
Gaseous emission (drying, firing)
Emission to air: dust
Noise
Solid Wastes
Waste Heat
Frit, Pigment and materials for glazes
Wastes
Traffic and Transport
Ceramic Products
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
Summary of enviromental aspects under normal conditions
INPUT
Env. Aspects
Production phase
raw material
water
OUTPUT
energy
gaseous emissions
watewater
waste
noise
heat
Body
Preparation
Forming
(Pressing)
Forming
(moulding)
Drying
Glaze
Preparation
Glazing
Firing
Finishing
Sorting
Packaging
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental aspects:
•
•
•
•
•
Raw Material Usage: ceramic products are manufactured mainly
from natural raw materials (clays, sands, feldspars, limestone etc)
Energy consumption: high – big consummer
Emissions to Air: represent the main environmental concern of
the industry: fluorine and heavy metals and VOC and combustion
gases
Emissions to Water: are mainly insoluble particulate matter
derived from material processing – so can be separated by
settling/filtration (often for re-use).
Waste: slurry from wastewater treatment, scrap, dangerous
waste – few: waste oil, etc...
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study:
A.3.1 Significant Environmental aspects and impacts
procedure
Conditions: normal, abnormal (shut-down, start-up and
maintenance) and emergency
•
•
past, on-going and planned activities,
Criteria: significant environmental impacts according to
requirement in Annex VI(6) of EMAS II:




Size (scale), severity and frequecy of the env. aspects
Fragillity of enviroment
Importance of stakeholders
Legal issues: Enviromental legislation or other requeriments
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental aspects procedure:
A.3.1
Maronagrés
Procedure
Purchases
Customers
Documentary Analysis
Identification of
Enviro nmental Aspects
Criteria are
Remained Valid
yes
no
Redefinitio n of
Criteria
Classification of
Enviro nmental Aspects
Significant Analysis
no
Classification
are Remained
Valid
yes
Approval
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental aspects procedure:
A.3.1 Maronagrés Env. aspects
Environmental Aspects
Environmental Impacts
Consumption of Water
Reduction of Natural
Resources
Production of
Gaseous Emissions
(from chimneys)
Atmospheric Pollution
Production of Fugitive
Emissions
(dusts and/or steams)
Atmospheric Pollution
Production of Liquids
Effluent
(industrials)
Environmental Aspects
Environmental Impacts
Production of Solid
Waste
Contamination of Soils
Consumption of
Electric Energy
Reduction of Natural
Resources
Consumption of
Natural Gas
Reduction of Natural
Resources
Consumption of Raw
Materials and Auxiliary
Reduction of Natural
Resources
Consumption of other
Materials / Resources
Reduction of
Resources
Hydric Pollution
Production of Liquids
Effluent
(domestic)
Hydric Pollution
Noise Production for
the Exterior
Noise Pollution
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Case study
“Implementation of EMAS in the Ceramic industry”
A.3.1 Maronagrés Env. aspects :
Criteria:
SCALE
SEVERITY
GRAVITY
CONTROL
PROBABILITY
/FREQUENCY
FRAGILITY OF
ENVIRONMENT
Stakeholder*
1
Intolerable
Catastrophic
Very critic
Uncontrollable
Very likely
Extreme risk to
ecosystem
Several
complaints
with NC
2
High
Severe
Critic
Exist but with
deficiencies
Likely
High risk to
ecosystem
Several
complaints
with no NC
3
Normal
Moderate
Moderate
Exist but with
some
deficiencies
Occasional
Moderate risk
One
complaints
with NC
4
Low
Mild
Marginal
Exist
Remote
Low risk to
ecosystem
One
complaints
with no NC
5
Very low not
reportable
Harmless
None
Exist and are
excellent
Unlikely
No risk to
ecosystem
No complaints
Classification of environment aspects
The significant environment degree (S) is made by:
S = F (fragility) * P (probability) * G (G=gravity = severity*scale) * C (control) *
I (Importance of stakeholders)
If S < 405, the impact is classified as significant or if there are legal issues
applicable.
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental aspects procedure:
A.3.1
Sanindusa 2
Procedure
Identification of aspects
environmental associates to
the activities, products and
services
Approval
No
Yes
Identification of environmental
impacts
Creation of criteria for
evaluation of environmental
aspects
Approval
No
Yes
Classification of the
environmental aspects
Manners of actuation for the
significant environmental
aspects
Register of the results of the
raising and classification in
identified folder
Divulgation of the significant
environmental aspects
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental aspects procedure:
Direct environmental aspects include:
emissions to air (from chimneys);s
releases to water (domestic and industrial);
production and treatment of wastes;
use of natural resources and raw materials (including water, natural
resources, electric energy and fuel);
local issues (noise, odor, dust, visual appearance, etc.);
transport issues (both for goods and services and employees);
risks of environmental accidents and impacts arising (or likely), as
consequences of incidents, accidents and pot. emergency situations;
Indirect environmental aspects include:
product related issues (design, development, packaging,
transportation, use and waste recovery/disposal);
the environmental performance and practices of contractors,
subcontractors and suppliers.
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental aspects procedure:
1
2
3
4
Moderate
Marginal
Low risk to
ecosystem
High
Severe
Very High
Catastrophic
Moderate risk
Extreme risk to
ecosystem
Duration (N)
Low
Harmless
No risk to
ecosystem or
confined zone
Exist and are
efficient
Sporadic
Exist but they con
be improved
Discontinuous
Probability
Unlikely
Not often
Size (scale)
Severity
Fragility of
environment
Control
Legal issues
Interested parties
Does not exist (N)
No complaint (N)
Exist but with
deficiencies
Continuous (8 <
hour/d<16
Occurs several
times
Don’t exist
Occurs always
Exist (Y)
Complaint (Y)
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Case study
“Implementation of EMAS in the Ceramic industry”
Maronagrés significant env. aspects:
A.3.2 Env. aspects
% of Significant Aspects
FA
9%
TRAN
PW
OF
DC
MARK
3%
4%
5%
BO and AT
12%
2%
3%
ETAR
PRE and DRY
6%
13%
AUX
2%
DEC
SUB
5%
MAN
4%
LAB
2%
POL e PEC
SOT
SP and CQ
11%
4%
5%
FIR
4%
7%
Environmental Performance
Index of Environmental Performance of the Section
10
9
8
7
6
5
4
3
2
1
0
BO and PRE and
AT
DRY
DEC
FIR
SP and
CQ
SOT
POL e
PEC
LAB
MAN
SUB
AUX
ETAR
PW
TRAN
FA
OF
DC
MARK
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Case study
“Implementation of EMAS in the Ceramic industry”
Sanindusa 2 significant env. aspects: A .3.2
Environmental aspects
Environmental impact
Consumption of
natural resources and
other
Use
of
natural
resources,
raw
materials and
other
Consumption
water
Consumption
energy and
fuels
of
of
fossil
Reduction of natural
resources
Indirect impact*
Reduction of resources
hydric
Saving of resources
hydric
(recirculation)
Reduction of resources
Indirect impacts*
PI- Pollution of the
soils, of the water and
of the air
Valorization interns
Production of wastes
Noise pollution
Environmental noise
Subjects of
local impact
Environmental aspects
Incidents, environmental
accidents and potential
emergency situations
Emissions to air
(punctual sources)
Transport
issues (raw
materials and
other)
Environmental impact
Atmospheric pollution
Contamination of Soils
PI - Pollution of the soils, of the
water and of the air
Atmospheric pollution
Mobil sources
Atmospheric pollution
Fugitive
emissions
Atmospheric pollution
Contamination of Soils
Discharge of liquid effluent
Domestic
Atmospheric pollution
Diffuse emissions
Industrial
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PI - Pollution of
the water and/or
soil
Contamination
of Soils
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Case study
“Implementation of EMAS in the Ceramic industry”
Sanindusa 2 significant env. aspects: A .3.2
1
3
Paste
reception
4
Finishing
(1ª phase)
Forming
15
12
14
WFP
Packaging
Productive
Process
13
Sorting
Finishing
(2ª phase)
11
Firing
6
7
Drying
9
Glazing
Verification
finishing
(3ª phase)
8
Assembly of
mechanisms
Glaze
preparation
Laboratory
2
WFP - Warehouse of
finished product
5
Pré-Drying
10
Maintenance
ETA
ETAR
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Case study
“Implementation of EMAS in the Ceramic industry”
Sanindusa 2 significant env. aspects: A .3.2
3, 7, 11
Emissions to air (from
chimneys)
Emission of the punctual
sources
Atmospheric pollution
All to monitor the chimneys sources (twice a
year)
To effect every six months analyzes of the
combustion parameters
To alter the constructive aspect of the chimneys
(to remove hat of the boiler and to increase the
remaining chimneys for 12,5 m)
2, 3, 4, 6, 8, 9, 11
ETA/ ETAR
Liquid effluent
Discharge of liquid
effluent
Water Pollution (after
treatment in ETAR)
To define rules for the operation of ETAR and
for emergency situations
1, 2, 3, 4, 6, 8, 9, 11, 12,
13, 14, 15
Maintenance and ETA/
ETAR
Wastes
Waste production –
industrial waste, green
ware, fired ware waste,
paper and card,
refractory, Oils, polluted
material, electric material
Potential impact - pollution
of the soil, air and waters
(due to the treatment of the
waste)
Valorization interns (green
ware waste)
To define good practices for the management of
the wastes (GAI secção)
The collaborators' sensitization to minimize the
production of wastes and to do her separation
(training)
1, 2, 4, 5, 6, 8, 9, 14, 15
Maintenance
Subjects of local
impact
Diffuse emissions
Contamination of the
ambient air (work place)
Atmospheric pollution
Emissions of movable
sources
Atmospheric pollution
Noise production
Noise pollution
Transport of raw
material and other
subsidiaries, wastes and
products
Transport subjects
DL n. º 78/04 of 3/04
Port n. º 286/93 of 12/03
DL n.º 236/98 of 1/08;
DL n.º 46/94 of 22/02
DL n. º 239/97 of 9/09; Port n.º
792/98 of 2/09; Port n.º 209/04 of
3/03; Port n.º 335/97 of 16/05
DL n.º 78/04 of 3/04
To define good practices conduction and
operation of automobiles for the subcontractors
(Poster)
DL n.º 132/04 of 3/06
Reduce emissions
of CO and SOx in
the firing
equipment (driers
and kilns and
boilers) in [number
%]
Minimize potential
for spills
Decrease of the
waste produce per
unit of production
Increase waste
management
--
Control of the
periodic vehicles
inspections
DL n.º 292/2000 of 14/11
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Case study
“Implementation of EMAS in the Ceramic industry”
Legal requirements:
Analyses of case-study
4.3.2 Legal requirements
•
Software system: mydox (developed by CTCV) –
compilation of Portuguese and European legislation
with an automatic up-date in 15 days;
•
Sites: www.dre.pt, www.ipq.pt and www.diramb.gov.pt,
www.eudor.com
•
permits, licenses or other forms of authorization;
•
register of applicable environmental legal requirements.
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Case study
“Implementation of EMAS in the Ceramic industry”
Objectives:
Analyses of case-study
A.3.3/4 Objectives, targets and programme(s)
Examples:
Environmental management program
Objectives and targets
Issues
Objective
Responsable
Raw materials
consumption
reduction of dangereous
waste on glaze materials
Water
consumption
reduction of water
Waste
reduction of waste
disposal to land-field
Targets
Activities
substitute completed
the XPTO pigment
used on the
composition
Reduction of 10% the
water consumption
compared with 2002
substitute totaly one of the
pigment used in glaze
preparation
XPTO
re-use 50% the water from the
wastewater treatment to
paviment cleaning
XPTO
Promote de segregation of
waste and recycling all green
Reduce 5% the waste scrapp in "forming" phase to
disposal in land-field "body preparation" phase
XPTO
compared with 2002
training the operators
Noise
to meet 55 dB(A) on
day and 45 dB(A) at
reduction of enviromental noise
nightlevel
all factory
Dealine
number of dangerous
June 2004 materials used
Set-04
m3 water/t production
Jan-04 t waste/ t production
XPTO
encapsulation of the ventilator
of the kiln
XPTO
Indicator
nº hours
Fev-04 noise level - dB(A)
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Case study
“Implementation of EMAS in the Ceramic industry”
Maronagrés Objectives, targets and programme(s):
Aspect
Objective
Several
Improve
employee training
Several
Subcontractors
Several
Create an audits
team from
collaborators
from Maronagrés;
Improve the
evaluation of
suppliers (quality
and environment);
Improve the
treatment of
nonconformities
Indicator
Actions/activities
Personal
responsible
Resources
Deadline
Follow up
Employee training in
environmental fields
([number]
hours/employee)
during the year 2004;
Create at least one
audits team from
collaborators from
Maronagrés until the 4º
trimester
At least 2 visits to
suppliers during the
year 2005;
Nº
hour/employee
a) training on environmental
fields
b) on job training the operational
control
c) emergency training
a) external training on quality and
environmental fields
DQA (director
of quality and
environment)
and human
resources
Director of
human
resources and
DQA
DQA
December
2004
Ever 3 months
External
entity
December
2004
Ever 3 months
a) perform at least 2 visits to
suppliers on matters related with
environmental fields
b) Send environmental
questionnaire
a) acquire a software
Environmental
department
(ED)
ED
December
2004
Semestrial
DQA
Software
from CTCV
December
2004
Ever 3 months
a) civil labor improvement in
tanks;
b) civil labor in involving area;
c) improve the tank efficiency
Maintenance
responsible
Civil
engineering
December
2004
Semestrial
a) acquire individual containers;
b) employee training in selective
collections of waste;
c) Final destination – licensed
company
Receiving and handling
procedures in the work place
Containers to avoid spill
Training in hazardous chemical
handling
Maintenance
responsible
and DQA
Containers
December
2004
Monthly
Production
manager and
environmental
department
Containers
and training
November
2004
Monthly
Informatics treatment
of all nonconformities
after the year 2004
Rehabilitation of the
wastewater treatment
facility during 2004
Wastewater
Rehabilitation of
the wastewater
treatment facility
Waste
Improve Waste
management
Emergency
aspects
Target
Minimize the
potential for spills
Nº audit teams
Number of visits
Visual and
efficiency
treatment
Selective collection of
all packing waste
(plastic, wood, metal,
paper, etc) during 2004
Nº of
improvements
Training in the
emergency situations
during the 2º semester.
Prepare the work
instructions
Number of
incidents or
accidents
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Other
informatio
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Case study
“Implementation of EMAS in the Ceramic industry”
Sanindusa 2- Objectives, targets and programme(s):
Aspect
Objective
SME
Improve employee
training
Waste
Improve Waste
management
Water
Improve Water
management
Waste
Decrease the waste
production
Energy
Use of natural gas
Gaseous emissions
Reduce emissions
of CO and SOx in
the firing equipment
Emergency aspects
Minimize the
potential for spills
Target
Employee training in
environmental fields 10
hours/employee during
the year 2004;
Selective collection of all
packing waste (plastic,
wood, paper) during 2004
Reduce the quantity of
water used per unit of
production in [number
%]
Indicator
Actions/activities
Personal
responsible
Resources
Deadline
Follow up
Nº hour/employee
a) training on EMS and
environmental aspects
b) on job training the operational
control
c) emergency training
a) acquire individual containers;
b) employee training in selective
collections of waste;
c) Final destination – licensed
company
To define good practice for the
management of the resource (work
instruction)
The collaborators' sensitization to
minimize the consumptions of water
(training and posters)
To define good practices for the
management of the wastes (work
instruction) The collaborators'
training to minimize the production
of wastes and their separation.
a) stop with the GPL use
b) used an UAG that produces
natural gas
a) use of natural gas
b) monitor the chimneys
c) control the burning of the kiln,
boilers, etc
Receiving and handling procedures
in the work place
Containers to avoid spill
Training in chemical handling.
Environment
department and
human resources
Training
December
2004 and 1º
semester
2005
Ever 3 months
Environmental
department (ED)
and production
manager
Containers
training
1º semester
2005
Monthly
Maintenance
responsible and
production
manager
Training
Civil
engineering
December
2005
Monthly
Technical and
production
managers
Containers;
training
December
2005
Ever 3 months
Production
manager
Civil
engineering
May 2004
Monthly
Production
manager
Technical
December
2005
semester
Production
manager and
environmental
department
Containers
and training
June 2005
Monthly
Nº of
improvements
m3 of Water/ton
Reduce the quantity of
waste per unit of
production in [number
%]
ton of Waste/ton
Use of natural gas in the
production during 2004
--
Reduce emissions of CO
and NOx in the firing
equipment (driers and
kilns and boilers) in 10 %
Training in the
emergency situations
during the 2º semester.
Prepare the work
instructions
Kg CO and Nox
per year
Number of
incidents or
accidents
ETIV - EMAS Technical Implementation and Verification31
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.1 Structure and responsability Maronagrés: integrated in Quality
The top management was appointed one of the top management directors
as a Management Representative for the coordination of the Quality
and Environmental Management System (QEMS)

The functions of the Director of Quality and
Environment are, among others:



to keep inform the Management Representative about the
performance, current status and progress of the QEMS;
to communicate with external entities related to the
QEMS;
to collected information to allow management to carry out
the management review process.
ETIV - EMAS Technical Implementation and Verification32
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.1 Structure and responsability -

The resource needed to implement and
maintain the EMS, have considered:



human resources (see organizational structure);
infrastructure technology and Technical resources;
financial resources
ETIV - EMAS Technical Implementation and Verification33
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.1 Structure and responsability A.4.1 Structure and responsability Sanindusa 2 : integrated with Quality, health and safety
The top management was appointed one of the top
management administrators as a Management
Representative for the coordination of the Quality,
Environmental and safety and heath Management System
(QESHMS).
The Environment responsible as the ultimately responsible for
the environmental system
ETIV - EMAS Technical Implementation and Verification34
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.2 Training, awareness and competence Training, awareness and competence Maronagrés: integrated in Quality
Sanindusa 2 : integrated with Quality, health and safety
Identify Training
Needs
Training Plan
Execution of the
Training Plan
Training Registers
Certified
Evaluation of the
Effectiveness of the
Training
ETIV - EMAS Technical Implementation and Verification35
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.3 Communication
Communication
process
Top
Management
Community in
(interested parties)
Communication
Community Out
Employees
ETIV - EMAS Technical Implementation and Verification36
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Case study
“Implementation of EMAS in the Ceramic industry”
Analyses of case-study :
A.4.3 Communication
Maronagrés: integrated in Quality, Plan, Measuring, etc ...
Sanindusa 2: procedure - integrated with Quality, health and safety
Internal communication:
•
Internal communication – placards (see examples in annex ?);
•
Minutes of meetings;
•
Training register;
•
Internal inquires (satisfaction)
•
electronic mail, · Intranet;
•
Information brochures (see examples in annex ?).
External communication medium types:
 Letter;
 Fax;  Telephone
 Email;  Internet;
 Visit to the ceramic industries
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Case study
“Implementation of EMAS in the Ceramic industry”
Documentation – Process aproach
Customers
=Satisfaction=
Customers
=Requirements=
Key Process
PC05
Development of New Products
PC02
Sales
Polishing Production
POL
Community
=Environmental
Impact=
PC01
Identification of the
Customers Needs
PC03
Production
Community
=Environmental
Legislation=
Production of Normal Product
NOR
PC04
Storage and Product Delivery
Production of Cut Special Pieces
PEC
Production of Pressed Special Pieces
PEP
Support Process
(1) No Quality and Environment
System Management
(2) Only Quality and Environment
System Management
PS-M05
Customer Satisfaction
Monitoring
PS-M04
Improvement and
Preventive Actions
Management
(3)
PS-M03
Nonconforming and
Corrective Actions
Management
(1)
PS-M02
Audit Management
PS-R08
Financial Management
(2)
PS-M01
Complaints Management
PS-R07
Heath and Safety
Management
(1)
Control and Improvement
PS-R06
Environmental Aspects
Management
PS-R05
Measuring and Monitoring
Devices Management
PS-R04
Maintenance
Management
PS-R03
Purchasing Management
PS-R02
Human Resources
Management
Resources Management
PS-R01
Quality and Environment
System Management
PS-D02
Business Plan
PS-D01
Management Review
Top Management
(3) Only activity 01 is Quality and
Environment System Management
ETIV - EMAS Technical Implementation and Verification38
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Case study
“Implementation of EMAS in the Ceramic industry”
Documentation
A.4.4. Documentation – integrated with Quality and health and safety:
1. Manual
1ºNível
MAN
2. Funcional procedures
2ºNível
PRC
3. Operative procedures –work instructions
4. Records
3º Nível
Descrição da Empresa e do SG Q&A
de acordo com a PolíticaQ&A
e com a NP EN ISO 9001:2000 e EMAS
Descrição das actividades relativas a cada
processo necessárias àmanutenção do SG
Q&A e implementaçãodos Objectivos da
Empresa
PL
4º Nível
ESP
IT MOP FR CAT TAB EXT
Funcional procedures:
Identifying and classification of Environmental Aspects;
Legal and other environmental requirements;
Competence, training and awareness - Q
Communication - Q
Emergency preparedness and response
Monitoring and measurement
Nonconformity, corrective and preventive actions - Q
Internal audit – Q – adictional requeriments - programme
Management Review - Q
ETIV - EMAS Technical Implementation and Verification39
Documentaçãoque define os parâmetros
e/ouvalores de trabalho necessários
àmanutenção do SG Q&A e implementação
Dos Objectivos daEmpresa
Descrição detalhadadas
actividades e documentos
de registo
39
Case study
“Implementation of EMAS in the Ceramic industry”
Documentation (2):
A.4.5 Document control
the control document procedure
(GSP001)
includes
the
documentation structure including
the titles, code numbers, dates,
version, revisions, revision history
or authority, approval, pages and
total pages.
The control is made to documentation
from
internal
and
external
sources.
Example of an informatics' program
for documentation management –
ISI 9000
ETIV - EMAS Technical Implementation and Verification40
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.6. Operational control
A.4.6. Operational control – procedures and work instructions:
Maronagrés:


integrated with previous quality work instructions (including purschasing) through
the process activities;
Specific procedures:
 Waste management;
 waterwater Treatment facility;
 Gaseous emissions treatment facility - fluorine;


Subcontracting;
Chemical substances
ETIV - EMAS Technical Implementation and Verification41
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.6 Operational control:
Sanindusa 2: two level approach : overall and specific


procedure for operational control – GAP004
Specific procedures:
GAP007 – Gestão de resíduos
GAP008 – Gestão de efluentes gasosos (in annex)
GAP009 – Gestão de efluentes líquidos
GAE001 – Requisitos ambientais para compras – environmental requirements in purchasing
GAI001 – Preenchimento das Guias de acompanhamento de resíduos;
GAI002 – controlo operacional da secção de preparação de vidro;
GAI003 – controlo operacional da secção de olaria;
GAI004 – controlo operacional da secção de secagem;
GAI005 – controlo operacional da secção de vidragem;
GAI006 – controlo operacional da secção de fornos;
GAI007 – controlo operacional dos resíduos de caco cozido;
GAI008 – Controlo Operacional da Manutenção – operational control in maintenance
GAI009 - Controlo Operacional da ETA e ETAR – operational control in ETA (water treatment facility)
and ETAR (wasterwater facility);
 GAI010 – controlo operacional do laboratório
 GAI011 – controlo operacional do armazém;
 GAI012 – controlo operacional avaliação de questionários;
 GAI013 – controlo operacional de serviços administrativos;
 GAI014 – Controlo das operações de trasfega – operational control on handling and transport ;














Subcontracting;
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Case study
“Implementation of EMAS in the Ceramic industry”
A.4.7 - Emergency
Identify Potencial
Emergency Situations
4.4.7 Emergency preparedness and
response
Identified emergency situation include:
Untreated wastewater discharges;
Chemical substances discharges including
(products for wastewater treatment,
solvents, glazes);
Fuel or Oil discharges; * Natural gas
release;
Particulates emissions (diffuse
emissions);
Firing; * Explosion;
natural disasters (e.g. flooding,
earthquakes)
Estab lish Emerg en cy
Plans and Procedures
Communication and
Training the Emergency
Plan / Procedure
Periodic Testing
Emergency Response
Procedures
No
Evaluation of the
Effectiven ess of the
Emergency Training
Yes
OK
ETIV - EMAS Technical Implementation and Verification43
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Case study
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A.4.7 Emergency
The emergency preparedness and response Plan include:
 general description of ceramic industry;
 location of the ceramic industry including a schematic map
of the facility, evacuation routes, location of environmental
emergency equipment, and assembly points;
 Identification of potentials environmental accidents and
emergencies;
 list of hazardous substances and quantities;
 emergency organization and responsibilitie;
 action procedure: written procedures to mitigation and
response actions to be taken to solve different types of
emergency situations or accidents.
 alarms;
 internal and external communication (e.g. neighborhood);
 distribution: list to whom the plan is distributed and the
responsible for distribution;
- EMAS Technical Implementation and Verification44
 ETIV
annex.
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Case study
“Implementation of EMAS in the Ceramic industry”
A.5.1 Monitoring and measuring
The environmental key characteristics are:






Waste management;
Gaseous emissions;
Water consumption;
Wastewater discharges (industrial and domestic);
Noise;
Energy.
ETIV - EMAS Technical Implementation and Verification45
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Case study
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A.5.1 Monitoring and measuring
Item.
Control
Name
Control
Work
Instruction Frequency Sampling Measurable
Variable
Operator
Record
TSS
External
reports,
validated by
environmental
responsible
pH
Total
Suspended
Clean Solids (TSS)
Water
Tank
pH
Chemical
Oxygen
Demand
(COD)
COD
Preconized
methods in
the legal
requirements
Once a
month
External
Sampling
Supplier of
the
Date of
treatment
of the
delivery
products
external
reports
External
entity with
the waste
water
treatment
plant
operator
Specification
Actions
External
Under Non
Communication
Conformity
Regulatory Requirement - License of Use
of the Hydric Public Domain
Example of monitoring plan in Maronagrés
Fill the
nonconformity
report
preventing at
minimum
industrial
director and
wastewater
plant
responsible
Define by quality
and environmental
director in view of
the risk of the
situation
Fill the
nonconformity
report
preventing at
minimum
industrial
director and
wastewater
plant
responsible
Quality and
environmental
director send to
official entity
(CCDR)
Copy of
external
Semestrial
reports,
validated by Communic
ation
quality and
environmental
director
<60 mg/l
6-9
<150 mg/l
ETIV - EMAS Technical Implementation and Verification46
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Case study
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A. 5.1 Monitoring and measuring
Example of monitoring plan in Sanindusa 2
MONITORING PLAN
Water
Consumption
Volume
(captation of
the puncture)
Dissolved or
Emulsified
Hydrocarbons
Technological
Oils and Fats
Water
Iron
Conductivity
Domestic
Volume
Liquid Effluent
Puncture
Puncture
After
Osmosis
Watermeter
Gaseous
Emissions
Quarterly
Not
Applicable
(n.a.)
Daily, Except
end
Weekend
Municipal
ETAR
Monthly
(sanitation
)
Exit of the
Soil
ETAR
SMEWW5520F Bulletin of
External
SMEWW5520C Essay
Sanindusa
Legal
Requirements
Responsible
Executant
Control Document
Methodology/
Norm/ IT
Not
Daily, Except
Reading in the
Applicable end
GAR xxx
water-meter
(n.a.)
Weekend
pH
Total Suspended
Industrial
Liquid Effluent Solids (TSS)
Frequency
Rejection Place
Sampling Place
Monitoring
Parameters
Environmental
Aspects
Monitoring of Environmental Parameters
Laboratory
DLn.º 46/94
de 22/02
Laboratory
--
Specifications / Conditions
Discharge
VMR/
VMA
VLE
Unid.
Freq.
Doc.
Ent.
2900
n.a.
m 3/month
n.a
n.a
n.a
µg/l
n.a
n.a
n.a
mg/l
n.a
n.a
n.a
µg/l
n.a
n.a
n.a
n.a..
m3
--
--
--
n.a..
6-9
Scale of
Sörensen
n.a..
60
mg/l
External Entity
SMEWW3120B
Sanindusa
Reading in the
GAR003
water-meter
Quarterly
Electrometry
Quarterly
Following
Filtration by
Drying and
gravimetry
Sanindusa
GA
Bulletin of
External
Essay
External Entity GA
GAR022
Liquid Effluent
CMC (Inova)
License of
Use of the
Hydric
Public
Domain
Semester
Chemical Oxygen
Demand (COD)
Quarterly
n.a..
150
mg/l
Auxiliary
Parameters
Biannual
n.a
n.a.
several
Flow
Biannual
n.a
n.a.
Nm 3/h
Particulates
Biannual
n.a
300
mg/Nm 3
CO
Biannual
n.a
1000
mg/Nm 3
n.a
1500
mg/Nm
4
n.a
50
mg/Nm 5
50
mg/Nm 6
NOx
Total Organic
Compounds
(TOC)
Fluoride
Heavy Metals
(Pb, Cd)
CO
Nox
CO2
Biannual
GAT003
Air
Instrumental
External
methods/ EPA/ Report
NP/ ISO/EN
GAR019
External Entity GA
Biannual
Biannual
n.a
Instrumental
method
INR - Institute of wastes ; DGE - General Direction of Energy
CCDR - Commission of Coordination of Regional
DLn.º
78/2004
Port
n.º286/93 de
12 de Março
n.a
Biannual
Semestrial
Sending of the Results
GAR023 e
GAR032
Sanindusa
GA
EPA - American Norms
EN - European Norms
n.a
Pb<5;
Cd<0,2
1000
1500
--
mg/Nm
7
mg/Nm
8
Bulletin
of
CCDRC
analysis
(ext)
Until 60
Bulletin
Days After
of
the
CCDRC
analysis
Measurem
(ext)
ents
--
--
--
ISO - International Norms
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Case study
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NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE ACTION
Examples of nonconformities can include:








Gaseous emissions, noise, water, wastewater or energy
reduction targets are not achieved;
Operating criteria (e.g. permitted limits) are not met;
Results from audits;
Records analysis;
Legal requirement and other analysis;
Complains from interested parties;
Records required of progress on objectives and targets are not
being kept;
Responsibilities are not assigned as required for an important
function of the EMS, such as emergency response;
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification48
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Case study
“Implementation of EMAS in the CeramicDetection
industry”
of
nonconformity
NONCONFORMANCE
Resolution of
nonconformity
NONCONFORMANCE AND
CORRECTIVE AND PREVENTIVE ACTION
Beginning of the
corrective action
Undesirable
situation
Register of the
corrective actions
Determination of
the probable
causes
Implementation of
the proposal
solution
Revision of the
corrective action
no
The solution
was efficient?
yes
Conclusion of the
action
Register of the
following of the
corrective actions
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification49
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Case study
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RECORDS
Maronagrés – informatics treatment
Some examples of environmental records include:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
Information on environmental aspects of the ceramic
industry;
Information on environmental indicator performance;
evidence of accomplishment of objectives/targets;
Information on applicable environmental laws and
regulations;
permits, licenses or other forms of legal authorization;
Monitoring and measuring data;
Calibration and maintenance activities of the
equipment;
Training records;
Decisions regarding external communication;
Information regarding contractors and suppliers;
results of operational controls;
details of nonconformities and corrective and
preventive actions;
Audit results;
Results of management reviews.
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification50
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Case study
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Au dit Program
EMS AUDIT
No
Nomination of
Auditors
EMS Audit integrated:
Aud it Plan
Quality – Maronagrés
Quality and heath safety –
Sanindusa 2
Conducting the audit include several
techniques and tools like ISO19011:2003,
checklist, observations, documents
consulted.
The internal EMS audits can be carried out
by personnel from the ceramic company,
by external auditors (consultant) or by a
combination of both
App roval?
Yes
Audits
No
Nonconformance?
Yes
Records of
Nonconfo rmance
Au dit Rep ort
Fonte: CTCV
Actions and
Evaluations
ETIV - EMAS Technical Implementation and Verification51
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Case study
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MANAGEMENT REVIEW
Management review integrated:
Quality – Maronagrés
Quality and heath safety – Sanindusa 2
The review cover the environmental aspects of activities, products
and services that are within the scope of the EMS.
The EMS of both ceramic industries should be reviewed at least once
a year in order to guarantee suitability, adequacy, and effectiveness
of the system. It is also analyse its integration with the overall
management system and its relationship to the current and
anticipated regulatory legislations
Fonte: CTCV
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Case study
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Environmental improvements achieved
Results and benefits:





reduction of the amounts of energy
consumed – process optimization;
Gaseous emissions treatment - fluorine;
Adopt of BAT (best available tecniques)
Noise reduction;
Natural gas - optimization.
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification53
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Case study
“Implementation of EMAS in the Ceramic industry”
Environmental improvements achieved
Results and benefits:



reduction of the amounts of energy
consumed – process optimization;
Adopt of BAT (best available tecniques)
Use of natural gas in substitution of
propane gas (GPL), provided by LNG
Storage tank
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification54
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Case study
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Environmental improvements achieved
selective collection of wastes produced;
Waste selective area;
Waste valorisation;
Rehabilitation of watewater facility
toner cartridges and ink cartridges
container;
Chemical substances container;
Minization of environmental accidents
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification55
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Case study
“Implementation of EMAS in the Ceramic industry”
Main Difficulties found in EMAS:
The Portuguese legal requirement on gaseous emissions: monitoring
all chimneys, chimneys high, etc ...
The waste final manager – not all legally authorized
The environmental noise, specially in the case of Maronagrés, has
the surrounding human house growth after the Maronagrés facilities
installations
Changing old practices …
Fonte: CTCV
ETIV - EMAS Technical Implementation and Verification56
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