Tees Valley Resource Efficiency Club Half Day Workshop Materials Management

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Tees Valley Resource Efficiency Club Half
Day Workshop Materials Management
John Binns Senior Consultant Atkins
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Domestics

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

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Agenda

• Introduction
• Resource Efficiency Programme
• Materials Management

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Materials Management
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Definition

• Raw materials are
• Materials that a manufacturer makes the products
  from

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Agenda

• Paper
• Oils
• Solvents
• Transport (fuel)

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Paper
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Calculating Cost of Paper Use
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Benchmark

• A best practice small office can use as little
  as seven reams of paper per person per year.

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Paper Purchasing

• What is its recycled content? How much
  post-consumer waste does it contain?
• Has the environmental impact of its manufacture
  been minimised?

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Paper Reduction

• Ensure that all photocopying and publications are
  produced in double sided format on recycled
  paper.
• Question whether you need to print draft copies
  at all.
• If this is unavoidable, print double-sided and
  then recycle.
• Put reminder posters near printers and
  photocopiers.
• Cancel junk mail and unwanted publications to
  reduce the amount of waste that has to be thrown
  away.

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Paper Reduction

• Avoid overproduction of marketing and publicity
  material by reviewing distribution lists and
  regularly updating databases.
• Use electronic communication where possible to
  reduce printing and faxing.
• Ensure that your staff are comfortable with new
  technology and provide training where necessary.
• Encourage them not to print out e-mails unless
  absolutely necessary.

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Paper Reduction

• Ensure fax machines are set so they do not
  produce unwanted header or report sheets.
• Reduce confidential waste costs by ensuring that
  the non-confidential paper collection is secure
  and give clear instruction to staff as to which
  material is strictly confidential.

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Paper Reuse

• Collect all paper that has been printed on one
  side and re-use it for printing in draft or for
  scrap message pads.
• Re-use envelopes wherever possible, especially
  for sending information internally.
• Donate surplus card or coloured paper to your
  local school or nursery.

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Paper Recycle

• Contact your local authority for details of paper
  recycling companies in your area.
• The frequency of collection and cost of recycling
  will depend on the amount of paper that you
  generate.
• Place paper recycling bins in all offices. A good
  guide is one bin between six staff and one next
  to each photocopier and printer.
• Use paper ream lids as additional desk top
  collection trays.

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Paper Recycle

• Promote the scheme to staff by putting up posters
  around the offices and on bins explaining the
  types of paper that can be recycled.
• Provide staff with on-going feedback about the
  scheme, including figures on the amount of paper
  collected. Suggest making a donation to charity
  or planting a tree when targets are met.
• Use 100 recycled paper (with maximum
  post-consumer waste content) as standard.

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Paper Recycle

• Ensure that service and maintenance warranties
  are not adversely affected by using recycled
  paper. There is no valid reason why they should
  be affected.
• Ensure that cleaning staff are in support of the
  recycling scheme and that emptying the recycling
  bins is part of their contracted work.

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Further Help

• Envirowise Guide
• Green officiency running a cost-effective,
  environmentally aware office

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Oils
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Oil

• Poorly managed oil systems can cost a lot of
  money, often in hidden costs, such as through
  avoidable machine breakdowns.
• With good control, oil use can be minimised and
  considerable savings made.

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Benefits

• Lubricants are vital, yet often overlooked,
  resources.
• 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

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Step 1 - Rationalise Oil Use

• There are many oils from different suppliers that
  do the same job.
• Using a smaller range of oils means they are
  easier to manage, with less chance of using the
  wrong oil, or of stored oil going out-of-date

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Step 2 - Measure to Manage

• Keeping simple records of oil use makes it is
  easy to highlight discrepancies from normal usage
  and take action before machines break down.

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Step 3 - Correct storage and handling

• Good storage can reduce contamination and the
  chance of spillage. For example, moving from
  drums to intermediate bulk containers (IBCs)
  means less waste and easier handling.
• Adtranz saved 1 100/year just from moving to
  IBCs. The same oil can be stored in far less
  space
• it is cheaper to buy IBCs and there are fewer
  spills and drips.

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Further Information

• Envirowise Guide
• Cost Effective Management of Lubricating and
  Hydraulic Oils GG227

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Solvents
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Benefits

• Improved solvent management can make companies
  more competitive and profitable by
• reducing the cost of buying solvents and
  solvent-containing materials such as inks,
  coatings
• and adhesives
• reducing waste disposal costs
• making it easier to comply with statutory
  controls on solvent use
• improving environmental performance
• reducing the need for pollution abatement
  equipment.

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Material Characteristics

• Where possible, look for low or no-solvent
  alternatives to solvent-based products.
• Discuss alternative materials with appropriate
  production staff and key suppliers.
• Many water-based and low VOC materials (inks,
  paints, adhesives, etc) are now available at a
  reasonable cost for many applications.

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Material Characteristics

• Where solvents and solvent-based products have to
  be used, consider issues such as health and
  safety, ease of storage, handling, etc.
• Chlorinated solvents need particular care for
  example, some chlorinated solvents can form acids
  when in contact with water, which can corrode
  metal.

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Buying in Bulk

• Buying in bulk by the tanker load or in
  intermediate bulk containers (IBCs) can
  significantly reduce costs and wastage in terms
  of packaging and material residues.
• It is sometimes possible to create tank and silo
  space without buying new tanks and silos by
  switching slower moving materials from bulk
  delivery to delivery in IBCs, drums or bags.

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Using Solvents in the Process

• Talk to suppliers, trade associations and other
  companies in your sector to identify new
  products, equipment and processes that can
  significantly reduce solvent use, e.g. compliant
  coatings and fully enclosed degreasing cabinets.
• Put lids back on partly emptied drums or cans of
  solvent and, where possible, make them airtight
  (egg seal with adhesive tape if the lid fits
  poorly).
• Keep solvent containers away from sources of heat
  and draughts to minimise evaporation.
• Encapsulate vessels, reservoirs and machinery as
  much as possible using well-fitting sealed lids
  and covers.

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Using Solvents in the Process

• Where reservoirs and containers do not have
  proper covers, use anti-static plastic covers
  (attached by elastic bands or nylon hook and loop
  fasteners, etc) or stretch-wrap.
• Such covers have the added advantage of keeping
  out dust and debris.
• When mixing solvents and coatings, pour the least
  volatile material first and the most volatile
  last to reduce losses.
• When thinning, eliminate residue losses (e.g. of
  coating) by using some of the thinning solvent to
  swill out the material from the container and add
  it to the mix.

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Using Solvents in the Process

• For manual processing, use precise measuring
  techniques (e.g. measuring jugs) rather than
  estimating the amount to be added.
• When decanting from large drums or IBCs, use
  measures of a known size (e.g. litre jugs) or
  mark the side of the container with set measures
  (e.g. 100, 200 litres) to prevent waste from
  over-estimation.
• When filling mixing vessels and machine
  reservoirs, reduce losses by avoiding splashing
  and excessive disturbance of the fluid surface,
  e.g. use drop pipes that pass to the bottom of
  the container.

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Using Solvents in the Process

• If pumping is not practical and pouring is
  necessary, use a funnel to reduce the risk of
  spillage. This is applicable to both virgin
  materials and waste solvents.
• Make all practicable efforts to minimise the
  amount of solvent-based material left in drums
  and other containers after emptying.
• For example, turn cans upside down and allow them
  to drain. Where this still leaves a residue (e.g.
  trapped around the filler neck) and where there
  is no significant risk of explosion, cans can be
  punctured or crushed and allowed to drain.

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Using Solvents in the Process

• Remove containers of residual solvent from
  working areas to safe storage areas (e.g.
  flammable liquid stores) regularly to avoid
  misuse and accidental spillage
• Ensure that any air extraction system (local
  exhaust ventilation) fitted to degreasing and
  mixing vessels is
• fitted above any lid
• interlocked to the lid and operates only when the
  vessel is open or when pressure increases require
  it.
• Optimise extraction rates to minimise VOC
  emission losses while maintaining a pleasant and
  safe workplace atmosphere Extraction rates are
  often set too high so as to err on the side of
  caution with regard to health and safety.

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Cleaning

• Examine all cleaning operations throughout the
  company to determine whether alternative cleaning
  solutions are already being used and, if they
  are, whether they can be applied in any other
  cleaning operations.
• Consider using low-VOC cleaning agents such as
  citrus/water-based and vegetable-based degreasing
  agents.
• Many alternative products are available and it
  may take several trials to identify the one that
  is best for your process.

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Cleaning

• Use only the minimum amount of solvent that is
  reasonably required for specific cleaning
  operations.
• Ensure that operators are given only the amount
  of solvent required to do the job, e.g. to clean
  spray guns at the end of a shift
• Spray a dose of cleaning solvent from a triggered
  dispenser rather than use an open can and rag.
  This will use less solvent and will reduce
  operator exposure.

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Cleaning

• Remove deposits as soon as possible following a
  clean as you go policy. A build-up of coating
  can become increasingly difficult to remove as
  time passes, and will require a disproportionate
  amount of effort and cleaning material.
• Where deposits have been left to dry, use a
  suitable scraper or squeegee first to avoid
  excessive solvent use.
• For general surface/floor cleaning, try using a
  detergent and warm water instead of solvent.
• For more difficult deposits, use a detergent
  solution in conjunction with mechanical measures
  such as scrapers, floor scrubbers and
  high-pressure water jets.

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Solvent Management Actions

• Examine the solvent route through the workplace,
  looking at each stage of solvent handling. For
  each stage, consider if you can make
  improvements.
• Review whether you need to use organic solvents
  at all or whether you could switch to a no
  solvent or low solvent alternative.
• Review your processes and procedures to see if
  you can eliminate or minimise solvent use and
  waste at all stages.

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Solvent Management Actions

• Raise the awareness of the need for good
  housekeeping when using solvents and train staff
  who handle solvents about how to avoid misuse,
  spills and leaks.
• Put in place procedures for dealing with spills
  and leaks.
• Investigate ways of improving delivery and
  storage methods.
• Implement a preventative maintenance programme
  for all machines and equipment.

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Solvent Management Actions

• Investigate and prioritise improvement options.
  Start by implementing no-cost and low cost
  measures that will bring quick and/or significant
  savings from reducing solvent use.
• Develop an action plan for your site with
  appropriate objectives, targets and defined
  responsibilities.

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Further Help

• Envirowise Guide
• Reducing Solvent Use by Good Housekeeping GG 413

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Transport
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Purchasing

• What is the whole-life cost of the vehicle?
  This includes the initial cost of he vehicle, its
  residual value, and fuel, maintenance and
  insurance costs.
• Could we use alternative fuels? Liquid natural
  gas (LNG) and compressed natural gas (CNG)
  vehicles are considerably cheaper to run than
  petrol or diesel vehicles owing to lower tax
  rates.

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Baseline Calculation
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Step 1 - Minimise the Need to Travel

• Plan staff commitments and use easily accessible
  conference venues to reduce travel.
• Locate any new offices close to public transport
  systems and publicise alternative transport links
  to visitors.
• Investigate the feasibility of home working or
  telecommuting for relevant employees. This need
  not apply to every working day and can
  significantly reduce the number of journeys staff
  make and maximise their working efficiency.
• Increase the use of communications technologies
  such as e-mail, ISDN and video conferencing.

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Step 2 Promote the use of efficient transport
modes

• Improve facilities for cyclists and walkers.
  Essentials are secure bike racks
• Offer interest-free loans for public transport
  season tickets. If you are a large organisation,
  try to negotiate discounts for your employees.
• Provide staff with up-to-date information on
  public transport.
• Promote car sharing. Establish a database or an
  informal meeting for prospective car sharers and
  guarantee a free taxi ride in an emergency.

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Step 2 Promote the use of efficient transport
modes

• Re-assess your car parking arrangements to
  include priority parking for car sharers, or
  charges for non-essential user parking. Use the
  money raised to fund transport projects.
• Change personal car mileage allowances to favour
  smaller cars and public transport - by having one
  rate only (instead of rates based on engine
  size), and making the maximum allowable claim no
  more than the cost of an equivalent second class
  rail fare.
• Monitor the fuel performance of each vehicle and
  ensure they are regularly serviced and maintained
  by a reputable garage.

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Step 2 -Promote the use of efficient transport
modes

• If your fleet management is out-sourced, ensure
  that you set high environmental standards within
  the contract and specify aspects such as fuel
  economy and emissions testing.

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Step 3 - Company Cars

• Purchase or lease fuel-efficient cars taking the
  whole-life costs into account - these can be
  calculated according to your projected usage.
• Some car magazines provide comparison tables for
  total running costs per mile.
• Give training in advanced driving practice - fuel
  consumption can be reduced by 25.

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Further Help

• Envirowise Guide
• Green officiency running a cost-effective,
  environmentally aware office

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Contact Details

• John Binns
• Senior Consultant
• 0191 2235230/ 0780 3260217
• john.binns_at_atkinsglobal.com