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What is Cleaner Production?
It is defined as a continuous application of an integrated preventative
environmental strategy applied to processes, products and services
to increase eco-efficiency and reduce risks to humans and the environment.
- Production processes -- conserving raw materials and
energy, eliminating toxic raw materials and reducing the quantity
and toxicity of all emissions and wastes.
- Products -- reducing the negative impacts along the
life cycle of a product, from raw material extraction to its
ultimate disposal.
- Services -- incorporating environmental concerns into
designing and delivering services.
Cleaner Production (CP) requires a shift in thinking away from
end-of-pipe treatment towards prevention, which frequently cuts
costs, reduces risks and identifies new opportunities. The focus
of CP is on prevention rather than on treatment and this requires
a change in process management, the reduction of excess inputs
and better utilisation of non-product outputs ("waste" and
by-products).
The following steps can be followed in the implementation of CP:
- Change of attitudes: New approaches to the relationship
between industry and environment (acknowledging the impact of
industry on the receiving environment) and re-designing an industrial
production process to ameliorate negative impacts.
- Applying know-how: Improving efficiency, better management
techniques, changing housekeeping practices.
- Improving technology: Changing process technology, input
materials, final product and reusing materials on-site.
The main components of Cleaner Production are as follows:
CP aims for waste minimisation by utilisation of efficient input
materials and recycling at source.
Efficiency in energy use, whereby efficiency is determined by
the highest ratio of energy consumption to product output achieved
through energy balance assessments.
- Safe and healthy work environments
CP strives to minimize the risks of workers in order to make
the workplace a cleaner, safer and healthier environment. In
applying CP companies can go beyond compliance of regulations
including safety standards through continuous reduction of toxins
and waste products.
- Environmentally sound products
Health and environmental factors must be addressed at the earliest
point of the product and process design and must be considered
over the full product life cycle, from production through the
use and disposal.
Steps towards implementing CP
To implement a CP programme in an institution or industry, information
on waste produced, emissions released and flaws in the production
process is very important. This information forms the bases for
setting reduction targets and options to be taken. Tools for gathering
information for CP implementation have been developed and one of
them is the UNEP/UNIDO CP assessment tool, as shown below:
UNEP/UNIDO Cleaner Production Assessment
Phase I: Planning and organisation
- Obtain management commitment
- Establish a project team
- Develop policy objectives and targets
- Plan assessment
Phase II: Pre-assessment
- Company description and flow chart
- Walk-through inspection
- Establish focus (areas with serious problems)
Phase III: Assessment
- Collection of quantitative data
- Material balance
- Energy balance
- Identify CP opportunities
- Record and sort options
Phase IV: Evaluation and feasibility study
- Preliminary evaluation
- Technical evaluation
- Economic evaluation
- Environmental evaluation
Phase V: Implementation and continuation
- Prepare an implementation plan
- Implement selected options
- Monitor performance
- Sustain CP activities
A company with Environmental Management System (such as ISO 9000
or 14001) can use its existing environmental management team to
do a CP assessment and implement the recommendations (options)
from the assessment.
Possible options for CP
CP options will usually be less costly to implement, operate and
maintain over the long term because of reduced costs for raw material,
energy, pollution control, waste treatment & cleanup and regulatory
compliance.
The following are reduced through a source reduction approach:
- Raw materials usage
- Hazardous waste generation
- Solid waste generation
- Inventory losses
- Spills and accidental releases
- Energy usage
- Water usage
- Environmental releases
The techniques used in source reduction are:
Is a procedure within a service or manufacturing operation,
which result in a reduction in waste generation.
Proper materials handling and storage ensures that raw materials
reach the production process without spills, leaks or other types
of losses, which could result in waste generation.
E.g. cleaning up spills and absorbents immediately, maintain
clean even surface in transportation areas, maintaining distance
between different types of chemicals to prevent cross-contamination.
A method of doing more with less by designing new systems or
modifying existing ones, the most effective means of conserving
materials and resources.
E.g. high-volume, low-pressure spray guns for painting operations
to minimise the amount of paint used.
Replacing hazardous chemicals with less toxic alternatives that
are equally or more effective.
E.g. use of water-based paints instead of organic solvent-based
paints, replacing organic solvent degreasers with aqueous cleaning
systems.
Reduce product losses due to product expiration and overstocking.
E.g. restricting access to supply areas, maintaining accurate
inventory records to prevent overstocking, validating shelf-life
expiration dates.
Includes any activity that might prevent equipment malfunctions
and minimise environmental releases.
E.g. routinely inspect equipment and storage containers, fixing
problems immediately, following standard operating procedures.
It is when materials are redirected back into the production
process.
E.g. water recirculation, multi-pass coolant systems.
What are the benefits?
- Reduction of operating costs
CP can reduce material costs by adopting product-packaging procedures
that consume fewer resources, which will also reduce waste management
and disposal costs.
- Reduction of ecological damage
CP reduces ecological damage from raw material extraction, refining
operations and the risk of emissions during production processes.
Employees, regulators and local residents are likely to feel
more positive towards a company when they recognize that management
is committed to providing safe working environment and to minimizing
pollution. CP implementation will also give a competitive edge
to a company.
- Reduction of civil and criminal liability
CP makes compliance with national, provincial and local regulations
easier and can also minimize the exposure of employees to harmful
substances, thus decreasing risk and saving money.
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