ENVIRONMENTAL MANAGEMENT PLANeia.met.gov.na/screening/392_emp_mpact_ministry_of... · 2019. 9....
Transcript of ENVIRONMENTAL MANAGEMENT PLANeia.met.gov.na/screening/392_emp_mpact_ministry_of... · 2019. 9....
ENVIRONMENTAL MANAGEMENT PLAN
2019
Mpact Corrugated (Pty) Ltd
Done by: Frans !Gaoseb & Adolfine Indongo
Date: 2 July 2019
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ENVIRONMENT POLICY STATEMENT
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Contents
1. Introduction ........................................................................................................................................... 3 2. Objectives of the EMP ........................................................................................................................ 3
3. Scope ..................................................................................................................................................... 4
4. Environmental Management System (EMS) ................................................................................... 4
4. Water Management ............................................................................................................................. 5
5. Land management ............................................................................................................................... 6 6. Air Quality Management ..................................................................................................................... 7
7. Waste Management ............................................................................................................................ 8
8. Resource Management .................................................................................................................... 10
9. Closure Plans ..................................................................................................................................... 11
10. Chemical Management ................................................................................................................... 12
11. Environmental Training and Awareness ...................................................................................... 14
12. Community Involvement ................................................................................................................. 14
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1. Introduction
Mpact Corrugated (Pty) Ltd is located in Walvis Bay in the Erongo Region of Namibia and is a carton manufacturing company that is both ISO 9001 (Quality Management System) and ISO 14 001(Environmental Management System) certified. The Operations that are undertaken at this site include corrugating, converting and printing. The organisation supplies cartons to the industrial, agricultural, meat, fish and beverage industries supplying more than 10 000 tons of packaging materials to customers per annum. More than 100 employees and contractors are employed at this company and it outsources processes related to Information Technology (IT), engineering, cleaning and security services. In order to produce the cartons various processes are followed as shown in Appendix 1. Two shifts work on the site, working from 06:00 – 16:00 and from 16:00 – 02:00 from Monday to Friday on a normal basis. The organisation is surrounded by the Dorob National Park. The municipal area (Walvis Bay) in which the organisation is located is however not included in this park and therefore the company is not subjected to restrictions applied to the National Park.
Mpact Corrugated (Pty) Ltd aim to support and protect the environment in which we operate.
Striving to cause as little damage to the environment as possible. The Environmental
Management Plan (EMP) addresses the management of the significant environmental impacts
related to the processes on site.
2. Objectives of the EMP
This document provides information on the mitigation measures designed to minimize or
eliminate the significant adverse impacts that may be caused by the site’s processes. The top
5 significant impacts derived through risk rating is as follows:
Aspects Impacts
Electricity usage at the Baler and the
Board Machine
Land, water & air pollution. Global warming (when fossil fuels are used for power generation)
Use of potable water for the Boiler,
ablution facilities and for drinking
Depletion of a natural resource.
Discharge of effluent water Eutrophication at the Municipal sewerage
site. (The impact is limited due to the fact
that less than 10% of the input water is
returned to the municipality. Water is
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treated at the effluent plant and re-used
for cleaning purpouses)
Generation of waste Land Pollution
Use of HFO at the Boiler Consumption of hydrocarbons, a non-
renewable resource.
Boiler Emissions Air pollution (Particulates, SO2, NOX, CO
& CO2)
Table 1
The primary objective of the EMP is to:
Describe actions taken for achieving the mitigation measures for the aspects/impacts,
Indicate responsibilities and frequencies of actions taken,
Legal compliance
3. Scope
This EMP (Environmental Management Plan) is applicable to the factory and the warehouse
located at 44 Third Street East, Walvis Bay.
4. Environmental Management System (EMS)
EMS is a structured framework for managing an organization’s
significant environmental impacts.
Mpact Corrugated is ISO 14 001:2015 certified by Bureau Veritas as part of a Divisional
Certificate. The ISO 14 001 certificate numbers is IND 16.6282 U/E.
The EMS is audited by both internal and external auditors against the ISO 14001:2015
standard and own procedures. This ensures the functionality of the EMS.
A non-conformance procedure is in place to handle environmental issues and involves
investigations into root causes and finding corrective actions.
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Management Review meetings are conducted twice a year to review the whole EMS. Daily
Kaizen meetings are held, providing a platform for discussing any environmental deviations
and solving them.
An annual training plan is set up so as to address the training needs of various departments
leading to a competent workforce and contributing towards a better management of the
environment.
An impacts/aspects register is available for various sections and reviewed on an annual basis.
The impacts of the aspects are classified as either high, medium or low based on a risk rating
that is a product of severity, frequency and exposure.
Objectives and Targets are set on an annual basis to address significant impacts.
An online legal register is available to the SHEQ Department, supervisors and managers.
Monthly updates are provided on changes in the Legislation that can affect the EMS.
4. Water Management
In 2011 a total of 7 927 m3 of water was used on the site compared to a projected total of 3
511 m3 in 2019 (calculated from the YTD June result of 1755 m3).
Projects as required by the ISO 14 001 standard are undertaken on an annual basis to reduce
water usage. Some of the projects undertaken in the last 3 years include the re-use of water
after treatment for cleaning activities at the Board Machine and to make starch batches that
are used in the manufacturing of cartons.
All effluent water used in the factory is channeled to the effluent plant which is contained
inside a bunded area. Sud-floc is used to treat the water up to acceptable levels. The treated
samples are send to Analab in Windhoek for analysis on a two monthly basis and the results
are compared against the Walvis Bay Municipal standards. An example of effluent results is
given in Appendix 2.
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To prevent water spills and the subsequent water pollution, the following measures are taken
Preventative maintenance on machinery and equipment
Employee training
Procedures for water management & for emergencies involving water spills
Spill Kits
Good housekeeping practices
The following activities are conducted on site on a periodic basis:
Activities / Objectives Targets Responsible
Person
1. Sampling and analysis of effluent water 1-2 months SHE
Coordinator
2. Recording water results in a database. This is
managed by the Municipality of Walvis Bay
Daily Municipality of
Walvis Bay
3. Treatment of effluent water at the effluent plant for
re-use or dispatch to the municipal sewers.
Daily to weekly Effluent
attendant
4. Setting targets for potable water consumption Annually Managers
Table 2
5. Land management
The land is primarily used for the manufacturing and converting of cartons. Some parts of the
land (Warehouse) are used to store paper reels and finished goods.
Measures are taken to prevent the contamination of the land above and below surface. An
Emergency preparedness and response procedure EMS OP 15 is available for the handling of
spillages of hazardous material, effluent and leaks and it also addresses fire emergencies.
Emergency teams have been appointed and relevant emergency numbers are placed on
notice boards. Fire escape signs are displayed in the factory and the warehouse with fire
fighting equipment placed at strategic points. Main Fire assembly points along with alternate
assembly points are available for various departments to meet and to conduct roll calls.
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Spill kits are available at various points to prevent the spread of a spilled substance and to
clean the contaminated area.
Most of the surfaces at Mpact where activities take place have a concrete/paved surface. In
the rare event that a hazardous chemical would spill on the soil, this soil will be removed as
quickly as possible and disposed of as hazardous waste.
Bunded walls are constructed for the following areas in order to contain spills:
• HFO tank area
• Effluent plant area
• Ink area.
Trenches are constructed at the waste storage area to contain any possible liquid waste,
although only solid waste is stored in this area.
Some other measures that assist with land management include the following:
Activities / Objectives Targets Responsible
Person
1. Cleaning of all areas Daily Cleaning Contractor
2. Removal of general waste As required Contractor
3. Removal of hazardous waste As required Contractor
4. Incineration of medical waste
(Municipal Landfill Site)
As required Clinic sister
5. Replace hazardous chemicals
with less hazardous ones.
As required SHEQ Department
Table 3
6. Air Quality Management
Mpact Corrugated strives to reduce air pollution by having annual targets on the use of fossil
fuels. The main fossil fuels used on site are HFO and LPG. The air emissions from the site are
directly proportional to the amount of fossil fuels used.
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The HFO and LPG usage is monitored on a monthly basis and is reported on a monthly basis
on the Mpact Database (Mpres) as well as in the local month-end reports. The principles of
continuous improvement as contained in the ISO 14 001 standard are applied on an annual
basis to reduce fossil fuel usage.
The following additional actions are taken to reduce air pollution:
Activities / Objectives Targets Responsible
Person
Service of the Boiler (includes calibration of the
conductivity probes, gauges & water level checks)
Monthly Maintenance
Foreman
Monitor the air quality emanating from the
Boiler stacks. Particles checked are: (O2, CO
& CO2)
Twice a
year
Contractor
Table 4
7. Waste Management
Waste separation is done at source. Waste stations are in each department with colour coded
wheelie bins and boxes. The separation of waste is done as follows:
Recyclable waste - Green wheelie bins. The bins are emptied in a skip collected by
Rent-a-drum for further recycling
Non-recyclable waste - Orange wheelie bins. The bins are emptied in a skip whose
contents are dumped at the general landfill site
Hazardous waste – Red wheelie bins. The final product end up at the municipal
incinerator or the hazardous landfill site
Metal waste – Black wheelie bins. Collected by the scrap metal dealer for further
recycling
Office paper – Collected in Slotted lid boxes. Baled on site and dispatched to Mpact Recycling (SA)
Cut off or waste cartons – Collected in metal cages. Baled on site and dispatched to Mpact Recycling (SA)
Electronic waste – Collected in Slotted lid boxes. E- Waste is given to Transworld
Cargo.
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Ink cartridges – Collected in Slotted lid boxes. Send to the municipal incinerator or
contractor for refilling.
Table 5 below gives an indication of the waste streams generated on site:
Principle Component of the waste stream
Waste Storage Area
Container Average monthly quantity generated
Duration of Storage
Classification (non-hazardous)
Disposal/ Resold/ Recycled/ sold as scrap
Chute waste (from extraction system of factory)
Outside Baler
None 101 tons 1 week non-hazardous
Recycled
Oil trench - in Area at waste skips
2.61m3 Waste Oil tank
0.87m3 6 months hazardous Recycled
Dies (these are separated into metal and wood)
Reel store None 1 <1 week hazardous Recycled
Stereos Reel store None 1 <1 week hazardous Disposal
Anvils Outside Baler
General waste Skip
2 <1 week hazardous Disposal
Reel ends (plastic stoppers)
Close to Corrugator
General waste Bin
97.7Kg <1 week non - hazardous
Recycled
Reel cores Close to Corrugator
Trolley 0.53 tons <1 week non - hazardous
Recycled
Shrink wrapping Next to conveyor system At Gate Control
General Waste Bin
1.41Kg <1 week non - hazardous
Recycled
Shrink wrapping cores Next to conveyor system At Gate Control
General Waste Bin
- <1 week non - hazardous
Recycled
Plastic strapping Where used at various Machines
General Waste Bin
292.56Kg Dependant on when max. Capacity is reached.
Non - hazardous
Disposal
Plastic strapping cores Where used and next to various units
General Waste Bin
- Dependant on when max. Capacity is reached.
non - hazardous
Sold
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PPE (gloves, breathing masks, ear plugs)
Where used in various Depts.
General Waste Bin
- Dependant on when max. Capacity is reached.
hazardous Disposal
Garden refuse (where applicable)
Removed Off - site by contractor
Plastic bags
on the spot Non - hazardous
Disposal
Building rubble Removed Off - site by contractor when generated
Asbestos (where applicable)
Removed Off - site by contractor when generated Hazardous Disposal
Effluent cake Removed Off - site by contractor when generated Non-hazardous
Disposal
Florescent tubes Removed Off - site by contractor when generated Hazardous Disposal
Table 5: Waste Streams on site
8. Resource Management
The management of natural resources is important in terms of sustainability. All raw materials
are used sustainably to ensure minimum wastage. The amount of natural resources used is
reported on a monthly basis on the internal reporting system. The main material inputs on site
include the following:
Paper
Starch
Water
Caustic Soda
Borax
Corwet
Glue
Ink (Water based)
HFO
LPG
Procedures are available and implemented for the manufacture of the starch mixture (starch,
water, caustic soda, borax and corwet) so as to prevent wastage.
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Software such as Shopware is used in the factory to monitor machine efficiency. The
efficiency of machinery is part of the key performance indicators of those working in the
factory including the General Manager. Improved efficiencies on the machine results in less
raw materials being used.
Paper waste is an important key performance indicator and is included in the performance
agreements of employees. The paper waste target for 2019 is 9% and the YTD June 2019
result is 8.9%.
9. Closure Plans
The need for accurate closure plans are an integral part of the Business. Some of the tasks to
be undertaken upon closure are specified in the table below:
Activities / Objectives Targets Responsible
Person
1. Form a committee for the closure project 3
months
before
closure
Management
2. Close out permits with the local municipality.
Applicable permits and renewal dates:
Business registration permit - 2020, Effluent
discharge permit - 2020, Flammable stores
permit - 2022, Waste removal permit - 2020.
Upon
Closure
SHEQ Department
3. Conduct a hazardous materials survey and
remove hazardous materials. These materials
include asbestos, lead, mercury, PCBs,
refrigerants, etc. Some of the potential sources of
hazardous material include building materials,
paint, switches, lights, ballasts, batteries,
transformers, and cooling systems.
3
months
before
closure
Qualified contractor
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4. Drain & Salvage the HFO and Boiler tanks.
The tanks will be sold to the scrap metal dealer.
Drained oil will be recycled.
Upon
Closure
Maintenance team
5. Evaluate the integrity of the wastewater
treatment plant tanks and chemical storage
containers. It will be scrapped and disposed of at
the appropriate landfill site. Chemicals used in
the wastewater treatment plant will be returned to
the supplier.
Upon
Closure
Maintenance team
6. Evaluate the structural integrity of the press
pits and process tanks associated with current
machinery. Remove for recycling or disposal.
Upon
Closure
Maintenance team
7. Inspect and drain the transformers. Test fluids
for PCB’s unless a record of prior testing and
certification is available.
Upon
Closure
Maintenance team
8. Return LPG cylinders to the supplier. Upon
Closure
Store man
9. Land rehabilitation – Consider options such as
the removal of possible contaminated soil, soil
washing, bioremediation, neutralization of the soil
, incineration of contaminated soil and
Containment of the polluted soil in cement or
other such materials if necessary. This is to
ensure that the land is safe for fauna and flora
and similar to surrounding undisturbed areas.
The rehabilitation should meet the standards as
set out by the local municipality.
Upon
closure
Specialist AIA.
Table 6
10. Chemical Management
Chemicals play a major role in everyday life. They are used extensively throughout Mpact Corrugated. Chemicals used on site include starch, caustic soda, borax, corwet, glue, ink, HFO, LPG and various oils and soaps.
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Major chemicals used on site are classified and labelled according to the United Nations Globally Harmonized System (GHS) and pictograms are provided to highlight the hazards. The Material Safety Data Sheets (MSDS) of chemicals are kept in files in the SHEQ
Department and is also presented at the relevant areas where chemicals are used.
Training is provided to employees who handle chemicals and this includes the use of MSDS
and handling of emergency situations involving the inhalation or ingestion of chemicals.
Only chemicals that are compatible are stored together, so as to prevent unwanted chemical
reactions.
Flammable chemicals such as oils and paints are stored in a flammable store which can
contain more that the volume of chemicals stored in it and is well equipped with fire fighting
equipment.
An LPG room is available with the correct ventilation and signage for filling LPG cylinders
used by forklifts as a source of fuel.
Some of the activities undertaken to facilitate safe handling of chemicals are listed below:
Activities / Objectives Targets Responsible
Person
1 An MSDS is requested for all new chemicals
that are purchased.
As required SHEQ & Buyer
2. MSDS are kept in files and also put up at all
chemical storage points. Through inspections it
is checked if all MSDS are present
Weekly SHE Coordinator
3. Follow Procedure EMS OP 03 – Handling &
Storage of Dangerous Goods & Hazardous
Waste. This procedure addresses the loading &
unloading of dangerous goods as well as
storage and the handling of new chemicals
Continuously SHEQ Department
Table 7
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11. Environmental Training and Awareness
Environmental training and awareness is provided to all employees on an annual
basis and includes Induction training, Toolbox talks, Awareness campaigns, HR
training and SHEQ training. The SHEQ training matrix for 2019 in included in
Appendix 3 for ease of reference. Supervisors and managers are also provided with
training on handling of non-conformances and this includes the finding of root causes
& corrective actions.
12. Community Involvement
Mpact Corrugated is a member of the Recycle Namibia Forum and involved in projects
promoting the three R’s namely Reduce, Re-use & Recycle in Namibia. Mpact
Corrugated also participate in clean-up operations and conducted a beach clean-up
operation on 7 June 2019 in celebration of World Environment Day (5 June 2019).
Mpact has participated in other projects in the community such as the Garden project
at JP Brand School, Utuseb in 2017/2018. It also conducted Mathematics tutoring
classes at Kuisebmund Secondary School, De Duine Secondary School, and
Flamingo Primary School & West Side High during the period 2015 to 2018. It
continues to sponsor Cancer Namibia events and other initiatives in Namibia.
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Appendix 1: Process Flow
Mpact Corrugated Namibia Process Flow -
Quality
Receipt of raw materials - paper
Reels of paper delivered by truck
Offload reels using clamp truck
Place reels into warehouse on
dunage
Starch KitchenMixing a batch of
starch
BoilerStarting the boiler to generate steam
Manufacturing of Board by Corrugator
Transport reel to Corrugator
Place reel into position
Cardboard scored, slit, chopped to size
& stacked by machine
Transfer board onto pallet
Receiving of raw other materials
Converting
Stacked board transferred to palletizer or converting
by forklift
Board fed into printing machine
Print boards Die cut boards
Cartons bundled and strapped
Strapped bundles packed on pallets
Transfer stacked bundles to palletizer
by forklift
Pallets transferred
Raw materials: starch, glue, dies,
palstic……….Machine parts
Pallitizer
Warehouse \ Dispatch
Ship finished goods to customer
Glue cartons
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Appendix 2: Effluent sample analysis
To: Mpact Corrugated (Pty) LtdP.O. Box 399
Walvis Bay Date received: 29-May-19
0 Date required: 0-Jan-00
Date completed: 7-Jun-19
Attn: Mr F. Gaoseb
mail: [email protected] Your Reference: PO 433340
Lab Reference: I190908
Sample details municipal effluent
Date of sampling 2019/05/28
Time of sampling 15:30
Test item number I190908/1
Parameter Value Units
p H 7.4 5.5-12
Conductivity 422 mS/m 450
Total dissolved solids (det.) 2401 0.94 mg/dm3
3000
Total suspended solids 30 mg/dm3
500
Chemical Oxygen Demand as O2 921 mg/dm3
1350
Sulphate as SO4 95 mg/dm3
300
Total phosphates as P 0.41 mg/dm3
30
Free & saline ammonium as N 100 mg/dm3
50
Chloride as Cl-
1175 mg/dm3
1500
Cyanide as CN-
<0.01 mg/dm3
2.5
Sulphide as S2-
<0.05 mg/dm3
10-50
Phenolic coumpounds as phenol 3.0 mg/dm3
Hexavalent chromium as Cr6+
<0.01 mg/dm3
0.5
Fat, oil and grease 4 mg/dm3
50
Sodium as Na 564 mg/dm3
1000
Iron as Fe 0.09 mg/dm3
10
Manganese as Mn 0.04 mg/dm3
5
Copper as Cu 0.01 mg/dm3
1
Zinc as Zn 0.03 mg/dm3
5
Boron as B 0.54 mg/dm3
5
Arsenic as As 0.01 mg/dm3
Selenium as Se 0.04 mg/dm3
5
Mercury as Hg <0.01 mg/dm3
0.005
Lead as Pb <0.01 mg/dm3
2
Cadmium as Cd <0.01 mg/dm3
0.5
Chromium as Cr <0.01 mg/dm3
Nickel as Ni 0.01 mg/dm3
4
Titanium as Ti 0.02 mg/dm3
Remark: * as supplied by client, valid from 1st January 2018
Current limit *
TEST REPORT
Municipality of Walvis Bay
Industrial effluent Standards
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Appendix 3: Training Matrix
Training Module Pro
du
cti
on
sta
ff
Main
ten
an
ce &
Dis
patc
h
Su
perv
iso
rs &
Man
ag
ers
Ad
min
istr
ati
on
Wh
k S
heetp
lan
t
Vis
ito
rs t
o p
rod
ucti
on
are
as/c
on
tracto
rs
All
vis
ito
rs
Fix
ed
Term
Co
ntr
acto
rs
Safety,Health,Environ
mental & Quality
Induction Feb-March Feb-March Feb-March Feb-March April - - Ad-hoc
Mpact - Safety Rules
to live by Feb-March Feb-March Feb-March Feb-March April - - -
MPSA Philosophy &
Principals Feb-March Feb-March Feb-March Feb-March April - - -
Safety meetings
(Toolbox talks) Monthly Monthly - - - - - -
Risk Assessment
Training July July July July - - - -
Forklift training Ad-hoc Ad-hoc Ad-hoc - - - - -
ISO 14 001
(Aspects/Impacts &
Emergency
Procedures) Oct Oct Oct Oct - - - -
Cartoons - Topic to
be decided April April April - - - - -
Cartoons - Topic to
be decided June June June - - - - -
PJO's Aug Aug Aug Aug - - - -
Sectional Induction
(show toilet, kitchen,
emergency assembly
points, dangers on
the machine) - - - - - Ad-hoc Ad-hoc Ad-hoc
Training presenters
Line Supervisor
Erastus Nakashona
External Trainers
Frans !Gaoseb
Adolfine Indongo
Erastus & Adolfine
J Dishena
SHEQ Team
Mpact Namibia - SHEQ Training Matrix 2019
Revision:
Doc no: EMS OR 13 Reviewed: F !Gaoseb
Owned by: HR Manager Effective Date: 01/01/2004