Case study: Implementation of EMAS in the Ceramic industry

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

2. 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 Case study “Implementation of EMAS in the Ceramic industry” Issues:

3. Case study “Implementation of EMAS in the Ceramic industry” Description of ceramic location

4. 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 Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

5. 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); Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

6. 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; Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

7. 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 Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

8. 2. Ceramic process description Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

9. Case study “Implementation of EMAS in the Ceramic industry” 2. Maronagrés ceramic process

10. 2. Sanindusa 2 ceramic process

11. 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) Case study “Implementation of EMAS in the Ceramic industry” Implementation of EMS - EMAS

12. 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) Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

13. 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)

14. 3. Significant Environmental aspectsand impacts procedure Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

15. Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

16. 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... Case study “Implementation of EMAS in the Ceramic industry” Environmental aspects:

17. A.3.1 Significant Environmental aspectsand 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 Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study:

18. A.3.1 Maronagrés Procedure Case study “Implementation of EMAS in the Ceramic industry” Environmental aspects procedure:

19. A.3.1 Maronagrés Env. aspects Case study “Implementation of EMAS in the Ceramic industry” Environmental aspects procedure:

20. Case study “Implementation of EMAS in the Ceramic industry” A.3.1 Maronagrés Env. aspects : 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.

21. A.3.1 Sanindusa 2 Procedure Case study “Implementation of EMAS in the Ceramic industry” Environmental aspects procedure:

22. 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. Case study “Implementation of EMAS in the Ceramic industry” Environmental aspects procedure:

23. Case study “Implementation of EMAS in the Ceramic industry” Environmental aspects procedure:

24. A.3.2 Env. aspects Case study “Implementation of EMAS in the Ceramic industry” Maronagrés significant env. aspects:

25. Case study “Implementation of EMAS in the Ceramic industry” Sanindusa 2 significant env. aspects: A .3.2

26. Case study “Implementation of EMAS in the Ceramic industry” Sanindusa 2 significant env. aspects: A .3.2

27. Case study “Implementation of EMAS in the Ceramic industry” Sanindusa 2 significant env. aspects: A .3.2

28. 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. Case study “Implementation of EMAS in the Ceramic industry” Legal requirements:

29. Analyses of case-study A.3.3/4 Objectives, targets and programme(s) Case study “Implementation of EMAS in the Ceramic industry” Objectives:

30. Case study “Implementation of EMAS in the Ceramic industry” Maronagrés Objectives, targets and programme(s):

31. Case study “Implementation of EMAS in the Ceramic industry” Sanindusa 2- Objectives, targets and programme(s):

32. 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.

33. 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

34. 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

35. Training, awareness and competence - Maronagrés: integrated in Quality Sanindusa 2 : integrated with Quality, health and safety Case study “Implementation of EMAS in the Ceramic industry” A.4.2 Training, awareness and competence -

36. Case study “Implementation of EMAS in the Ceramic industry” A.4.3 Communication Communication process

37. 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 Case study “Implementation of EMAS in the Ceramic industry” Analyses of case-study :

38. Case study “Implementation of EMAS in the Ceramic industry” Documentation – Process aproach

39. 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 Case study “Implementation of EMAS in the Ceramic industry” Documentation

40. 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

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

42. 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; Case study “Implementation of EMAS in the Ceramic industry” A.4.6 Operational control:

43. 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) Case study “Implementation of EMAS in the Ceramic industry” A.4.7 - Emergency

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

45. 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.

46. Case study “Implementation of EMAS in the Ceramic industry” A.5.1 Monitoring and measuring • Example of monitoring plan in Maronagrés

47. Case study “Implementation of EMAS in the Ceramic industry” A. 5.1 Monitoring and measuring • Example of monitoring plan in Sanindusa 2

48. 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; Case study “Implementation of EMAS in the Ceramic industry” NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE ACTION Fonte: CTCV

49. NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE ACTION Case study “Implementation of EMAS in the Ceramic industry” NONCONFORMANCE Fonte: CTCV

50. Case study “Implementation of EMAS in the Ceramic industry” RECORDS • 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. Fonte: CTCV