Case study

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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
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Issues
Case study Implementation of EMAS in the
Ceramic industry

• Structure of the ceramic study-case
• Ceramic process
• Development of an EMS according to EMAS II
• Enviromental improvement - photos
• Main difficulties - photos
• Training material
• ETIV Main difficulties

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Description of ceramic location
Case study Implementation of EMAS in the
Ceramic industry
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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 1. Study case structure
• Part 1
• Description of the company
• Maronagrés ceramic tiles company certified by
  ISO90012000
• Sanindusa 2 Sanitaryware company
• Brief summary of the case study
• Driving forces and Benefits of EMAS

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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 1. Study case structure
• Part 2 Case studies PDCA MODEL Plan-
  Do-Check-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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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 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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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 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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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 2. Ceramic process description

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Case study Implementation of EMAS in the
Ceramic industry

• 2. Maronagrés ceramic process

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• 2. Sanindusa 2 ceramic process

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Implementation of EMS - EMAS
Case study Implementation of EMAS in the
Ceramic industry

• 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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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 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 (QE) 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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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 3. Significant Environmental aspects and impacts
  procedure

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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry
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Environmental aspects
Case study Implementation of EMAS in the
Ceramic industry

• 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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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 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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Environmental aspects procedure
Case study Implementation of EMAS in the
Ceramic industry

• A.3.1
• Maronagrés
• Procedure

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Environmental aspects procedure
Case study Implementation of EMAS in the
Ceramic industry

• A.3.1 Maronagrés Env. aspects

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A.3.1 Maronagrés Env. aspects
Case study Implementation of EMAS in the
Ceramic industry

• Classification of environment aspects
• The significant environment degree (S) is made
  by
• S F (fragility) P (probability) G
  (Ggravity severityscale) C (control) I
  (Importance of stakeholders)
• If S lt 405, the impact is classified as
  significant or if there are legal issues
  applicable.

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Environmental aspects procedure
Case study Implementation of EMAS in the
Ceramic industry

• A.3.1
• Sanindusa 2
• Procedure

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Environmental aspects procedure
Case study Implementation of EMAS in the
Ceramic industry

• 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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Environmental aspects procedure
Case study Implementation of EMAS in the
Ceramic industry
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Maronagrés significant env. aspects
Case study Implementation of EMAS in the
Ceramic industry

• A.3.2 Env. aspects

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Sanindusa 2 significant env. aspects A .3.2
Case study Implementation of EMAS in the
Ceramic industry
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Sanindusa 2 significant env. aspects A .3.2
Case study Implementation of EMAS in the
Ceramic industry
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Sanindusa 2 significant env. aspects A .3.2
Case study Implementation of EMAS in the
Ceramic industry
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Legal requirements
Case study Implementation of EMAS in the
Ceramic industry

• 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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Objectives
Case study Implementation of EMAS in the
Ceramic industry

• Analyses of case-study
• A.3.3/4 Objectives, targets and programme(s)

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Maronagrés Objectives, targets and programme(s)
Case study Implementation of EMAS in the
Ceramic industry
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Sanindusa 2- Objectives, targets and programme(s)
Case study Implementation of EMAS in the
Ceramic industry
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A.4.1 Structure and responsability -
Case study Implementation of EMAS in the
Ceramic industry

• 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.

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A.4.1 Structure and responsability -
Case study Implementation of EMAS in the
Ceramic industry

• The resource needed to implement and maintain the
  EMS, have considered
• human resources (see organizational structure)
• infrastructure technology and Technical
  resources
• financial resources

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A.4.1 Structure and responsability -
Case study Implementation of EMAS in the
Ceramic industry

• 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

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A.4.2 Training, awareness and competence -
Case study Implementation of EMAS in the
Ceramic industry

• Training, awareness and competence -
• Maronagrés integrated in Quality
• Sanindusa 2 integrated with Quality, health and
  safety

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A.4.3 Communication
Case study Implementation of EMAS in the
Ceramic industry

• Communication process

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Analyses of case-study
Case study Implementation of EMAS in the
Ceramic industry

• 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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Documentation Process aproach
Case study Implementation of EMAS in the
Ceramic industry
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Documentation
Case study Implementation of EMAS in the
Ceramic industry

• A.4.4. Documentation integrated with Quality
  and health and safety
• Manual
• Funcional procedures
• Operative procedures work instructions
• Records
• 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

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Documentation (2)
Case study Implementation of EMAS in the
Ceramic industry

• 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

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A.4.6. Operational control
Case study Implementation of EMAS in the
Ceramic industry

• 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

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A.4.6 Operational control
Case study Implementation of EMAS in the
Ceramic industry

• 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

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A.4.7 - Emergency
Case study Implementation of EMAS in the
Ceramic industry

• 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)

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A.4.7 Emergency
Case study Implementation of EMAS in the
Ceramic industry

• 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
• annex.

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A.5.1 Monitoring and measuring
Case study Implementation of EMAS in the
Ceramic industry

• The environmental key characteristics are
• Waste management
• Gaseous emissions
• Water consumption
• Wastewater discharges (industrial and domestic)
• Noise
• Energy.

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A.5.1 Monitoring and measuring
Case study Implementation of EMAS in the
Ceramic industry

• Example of monitoring plan in Maronagrés

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A. 5.1 Monitoring and measuring
Case study Implementation of EMAS in the
Ceramic industry

• Example of monitoring plan in Sanindusa 2

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NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE
ACTION
Case study Implementation of EMAS in the
Ceramic industry

• 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
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NONCONFORMANCE
Case study Implementation of EMAS in the
Ceramic industry

• NONCONFORMANCE AND
• CORRECTIVE AND PREVENTIVE ACTION

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50
RECORDS
Case study Implementation of EMAS in the
Ceramic industry

• Maronagrés informatics treatment
• Some examples of environmental records include
• a) Information on environmental aspects of the
  ceramic industry
• b) Information on environmental indicator
  performance
• c) evidence of accomplishment of
  objectives/targets
• d) Information on applicable environmental laws
  and regulations
• e) permits, licenses or other forms of legal
  authorization
• f) Monitoring and measuring data
• g) Calibration and maintenance activities of the
  equipment
• h) Training records
• i) Decisions regarding external communication
• j) Information regarding contractors and
  suppliers
• k) results of operational controls
• l) details of nonconformities and corrective and
  preventive actions
• m) Audit results
• n) Results of management reviews.

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51
EMS AUDIT
Case study Implementation of EMAS in the
Ceramic industry

• EMS Audit integrated
• Quality Maronagrés
• Quality and heath safety Sanindusa 2
• Conducting the audit include several techniques
  and tools like ISO190112003, 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

Fonte CTCV
52
MANAGEMENT REVIEW
Case study Implementation of EMAS in the
Ceramic industry

• 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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Environmental improvements achieved
Case study Implementation of EMAS in the
Ceramic industry

• 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
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Environmental improvements achieved
Case study Implementation of EMAS in the
Ceramic industry

• 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
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Environmental improvements achieved
Case study Implementation of EMAS in the
Ceramic industry

• 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

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Main Difficulties found in EMAS
Case study Implementation of EMAS in the
Ceramic industry

• 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

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