CLEANER PRODUCTION

INTRODUCTION TO (CP)
CONCEPTS AND PRACTICE

Prepared by the Institute of For UNEP, Division of

Environmental Engineering Technology, Industry, and
(APINI) Kaunas University of Economics
Technology, Lithuania

Passive environmental
strategies
Dilute & disperse

1
 Reactive environmental
strategies
end-of-pipe approaches

Reactive environmental
strategies
On - site recycling

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 Proactive environmental
strategies:
Cleaner Production

Prevention of Waste
generation:
- Good housekeeping
- Input substitution
- Technology change
- On-site recovery/reuse
- Product modification

Cleaner Production Definition

“The continuous application of an integrated

preventive environmental strategy applied to
processes, products, and services to increase
overall efficiency and reduce risks to humans and
the environment.”

(United Nations Environment Programme)

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 Cleaner Production

is a Preventive Integrated Environmental Policy

applied to the entire Production and Service cycle

Products: Processes:
•Reduction of waste •Conservation of raw materials, Services:
through better design energy, water •Efficient environmental
•Use of waste for •Reduction of emission at source management in design
new products •Evaluation of technology option and delivery
•Reduction of costs and risks

Impacts:
Improved efficiency
Better environmental performance
Increased competitive advantage

Properly implemented CP :

always
• reduces long-term liabilities which
companies can face many years
after pollution has been generated
or disposed at a given site

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 Properly implemented CP :

usually
 increases profitability
 lowers production costs
 enhances productivity
 increases product yield
 leads to the more efficient use of energy
and raw materials

Properly implemented CP :
usually (continuation)
 results in improved product quality
 increases staff motivation
 relies on active worker participation in
idea generation and implementation
 reduces consumer risks
 reduces the risk of environmental
accidents
 is supported by employees, local
communities, customers and the public
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 Properly implemented CP :

often
 avoids regulatory compliance costs
 leads to insurance savings
 provides enhanced access to capital
from financial institutions and lenders
 is fast and easy to implement

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Cleaner Production practices

Technological Good Operating

Change Practices

Change in
PROCESS Product
Changes
Raw Materials

Onsite Reuse
& Recycling

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Input material change (material purification or
substitution)

substitute input materials

- by less toxic
- or by renewable materials
- or by adjunct materials which have a longer service life-
time in production

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Technology changes

replacement of:
- the technology/process substitution
- processing sequence
- synthesis pathway

• Optimal process conditions

• Increased automation
• Improved process control
• Improved equipment design and lay-out

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 Equipment modification

modify the existing production equipment and utilities

in order to:
- run the processes at higher efficiency
- lower waste and emission generation rates

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Good Operating Practices (Good housekeeping)

take appropriate managerial and operational actions to

prevent:
- leaks
- spills
- to enforce existing operational instructions

• Material handling and inventory practices

• Loss prevention
• Waste segregation
• Production scheduling of batch runs

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 On-site recovery/reuse

- reuse of the wasted materials in the same process

for another useful application within the company

Production of a useful by-product

• consider transforming waste into a useful by-product,

to be sold as input for companies in different business
sectors (Off-site reuse)

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Product modification/improvement

modify the product characteristics in order:

- to minimise the environmental impacts of the product

during or after its use (disposal)

- to minimise the environmental impacts of its production

• Product substitution (water based paints)

• Product reformulation (gasoline)

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CP versus End-of-Pipe approach

Cleaner Production Pollution Control and Waste

Management

Continuous improvement One-off solutions to individual

problems
Progress towards use of closed loop Processes result in waste materials for
or continuous cycle processes disposal in a pipeline with resources
in and wastes out

Everyone in the community has a Solutions are developed by experts

role to play; partnerships are often in isolation
essential
Active anticipation and avoidance of Reactive responses to pollution and
pollution and waste waste after they are created

Elimination of environmental Pollutants are controlled by waste

problems at their source treatment equipment and methods

Involves new practices, attitudes

and management techniques and Relies mainly on technical
stimulates technical advances improvements to existing technologies

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 What is not CP?

• Off-site recycling

• Transferring hazardous wastes

• Waste treatment

• Concentrating hazardous or toxic constituents to

reduce volume

• Diluting constituents to reduce hazard or toxicity

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What are the benefits of

Cleaner Production?
Improving
environmental situation

Increasing Social (health and

economical benefits safety)

Gaining
competitive
Increasing
advantage
productivity
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Cleaner Production Benefits:
1. CP adds value to the EMS: it places emphasis on pollution
prevention rather than control, with clear improvement in
environmental performance.
2. CP does not deny or impede growth but insists that
growth can be ecologically sustainable.
3. CP is not limited only to manufacturing industries of a
certain type or size, it can be applied towards the provision
of services also.
4. CP includes safety and protection of health.
5. CP emphasizes risk reduction.
6. CP improves immediate efficiency as well as long-term
efficacy.
7. CP is Win-Win-Win factor: it benefits the environment,
communities and businesses.
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CP barriers

- Lack of information and

Internal to the companies: expertise
- Low environmental
awareness
- Competing business
priorities, in particular, the
pressure for a short term
profits
- Focus on end-of-pipe
solutions
- Financial obstacles
- Lack of communication in
firms
- Middle management inertia
- Labour force obstacles

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 CP barriers

External to the companies:

-Difficulty in
accessing
cleaner
The failure technologies
of existing
regulatory
approaches -Difficulty in
accessing
external
finance

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CP motivators and drivers

Internal to the companies:

- Improvements in productivity
and competitiveness
- Environmental management
systems and continuous
improvement
- Environmental leadership
- Corporate environmental
reports
- Environmental accounting

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 CP motivators and drivers
External to the companies:

- Innovative - Soft loans

regulation from
Financial
- Economic institutions
incentives
- Community
- Education involvement
and
training - International
trade
- Buyer – incentives
supplier
relations

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The role of
international organizations in CP
development
• United Nations Environment Programme (UNEP)

• United Nations Industrial Development Organisation

(UNIDO)
• Organisation for Economic Co-operation and Development
(OECD)
• World Business Council for Sustainable Development
(WBCSD)
• Development Finance Institutions (DFIs)

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 Team for CP success

• Managers, engineers and finance people in industry

and commerce, in particular those responsible for
business strategy, product development, plant
operations and finance

• Government officials, both central and regional, who

play an important role in promoting CP

• Media representatives who play an important role in

disseminating information on good environmental
practices

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Cleaner Production procedures

The recognized need
to minimise waste

The first Planning and

step Organization

The second Assessment

step Phase

The third Feasibility Analysis

step Phase

The fourth
step
Implementation

Successfully implemented CP projects 30

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CP Methodologies

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1. Planning & Organization

• Obtain management commitment

• Identify potential barriers and solutions

• Set plant-wide goals

• Organize a project team

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 2. Assessment

• Identify sources

• Identify waste/ pollution causes

• Generate possible options

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Material and energy balances

Heat Power The

Energy
Balance

Raw The Industrial Products

Materials & Waste
Process

The
Cooling Mass
Balance

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 Why are material and energy
balances so important?
The material and energy balances are not only used to identify the
inputs and outputs of mass and energy but their economic
significance is related to costs, such as:

• cost of raw material in waste

• cost of final product in waste
• cost of energy losses
• cost of handling waste
• cost of transporting waste
• cost of solid wastes disposal
• cost of pollution charges and penalties

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Some Key
Environmental Indicators

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 Possible causes for waste
generation

Choice of Technical
Production Status of
Technology Equipment

Choice &
Quality of Process Process
Efficiency
Input Materials

Personnel
Wastes &
Skills &
Emissions
Motivation

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Option generation (1)

• Creative Problem Solving (CPS):
- Find facts
- Identify the problem
- Generate ideas to solve the problems
- Define criteria to be used to select solutions/ideas

• Screening of ideas / options:

- Select all ideas/options that may be implemented immediately
- The remaining options/ideas should then be divided into three boxes:
- Good housekeeping
- Interesting options but more analysis is needed
- Waiting box + Rejected

• Questions to prioritise options in second group:

- What are the main benefits to be gained by implementing this option?
- Does the necessary technology exist to implement the option?
- How much does it cost? Does it appear to be cost effective, meriting
in depth economic feasibility assessment?
- Can the option be implemented within a reasonable timeframe
without disrupting production? 38

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 Option generation (2)
Traditional brainstorming

• Formulate problem (problem

identification)
• Define objective of the
brainstorming session
• Follow the rules of brainstorming:
- Select a secretary to write
down all ideas (The secretary
can't take part in the idea
generation)
- Select a group leader (the
group leader shall control that
the four main rules are
followed)
• Close the idea generation after
30-40 minutes
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CP assessment practices

Good Input Better Process

Housekeeping Substitution Control

Equipment
Modification
Process Technology
Change

On-site Production of
Recovery/ Product
Useful Modification
Reuse By-Product

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 3. Feasibility Studies

• Preliminary evaluation
• Technical evaluation
• Economic evaluation
• Environmental evaluation
• Selection of feasible options

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Payback Period

Capital investment
_____________________________
Payback period =
Annual operating cost savings

- period of time (years) needed to generate enough cash

flow to recover the initial investment

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 4. Implementation &
Continuation

• Prepare a CP plan
• Implement feasible CP measures
• Monitor CP progress
• Sustain Cleaner Production

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CP attacks the problem at several

levels at once. The implementation of
an industry/plant level programme
requires,

- the commitment of top management

- a systematic approach to CP in all
aspects of the production processes

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 CP management system
Marketing

Top management
commitment

Pre-assessment

CP policy
declaration

Start CP project

Top Management reviews Project organization

Final report Assessment

The continuous
CP loop
Measure progress CP options

Project implementation Feasibility analysis

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Assessment report

CP and main stakeholders

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 How can governments
promote CP?

 Applying regulations
 Using economic instruments
 Providing support measures
 Obtaining external assistance

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CP applicability for local

governments

 Corporate decision-making
 Local environmental management strategies
 Community and industry partnerships
 Sustainable economic development
 Public environmental education
 Specific local environmental problems
 Local environmental monitoring

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 CP and financial institutions
Environmental evaluation can help:

•Establish an exclusion list

•Identify environmental
risks in every project
•Understand the financial
institution’s exposure to
environmental risks and
liabilities
•Monitor the environmental
risks of transactions and
respond
•Evaluate risks and
liabilities in foreclosure or
re-structuring activities
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Overall Risk Profile

CONSUMERS’ NEW
WORKERS’ HEALTH REGULATIONS
ENVIRONMENTAL
HEALTH ACCIDENTS

RISKS
LIABILITY REPUTATION

CLEAN--UP
CLEAN
BUSINESS VALUE
INSURANCE
PRODUCT SALES
CLAIMS
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If a CP project is presented to a financial
institution, it should be clear that the
company already undertook voluntary actions
aimed at:
 rationalising the use of raw materials, water and energy
inputs, reducing the loss of valuable material inputs and
therefore reducing operational costs
 reducing the volume and/or toxicity of waste, wastewater
and emissions related to production
 improving working conditions and occupational safety in
a company
 making organisational improvements
 improving environmental performance by the
implementation of no-cost and low-cost measures from
the company’s funds
 reusing and/or recycling the maximum of primary inputs
and packaging materials

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Environmental investment
opportunities
 loans to enterprises to finance required or desired
investments in technologies resulting in direct and
indirect environmental benefits
 loans to municipalities to finance investments in
environmental infrastructure
 loan guarantees to both enterprises and
municipalities for “soft” credits from national or
regional environmental funds for environmental
investments
 loans to finance businesses providing
environmental goods and services

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 Broader Application of CP

CP is closely linked to:

• Environmental Management Systems
• Total Quality Management
• Health and Safety Management

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Cleaner Production and

Sustainable Development

Sustainability
Responsible
Entrepreneurship

Eco-efficiency

Cleaner Production

Compliance

Government Sustainable
Agenda development

Business EHS
EMS
Agenda Auditing
Time

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 !!!
CP is
a journey
not a
destination
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