Pilot Project Chemical Safety

bySusanne Scholaen

Tulpenfeld 2, 53113 Bonn, GermanyTel: +49 228 9857015

email: gtzscholaen@aol.comweb: www.gtz.de/chs/

13. 02. 2003 IPCS Geneva 2

Pilot Project Chemical Safety

By order of the:

Federal Ministry for Economic Cooperation and Development (BMZ)in technical cooperation with the:

German Federal Ministry for the Environment, Nature Conservation and Reactor Safety (BMU)

13. 02. 2003 IPCS Geneva 3

Pilot Project Chemical Safety

Provides assistance to developingcountries or countries with economies in transition:

• In the framework of Agenda 21, Chapter 19 on the sound handling of chemicals

• In the implementation of the Rotterdam (PIC) and Stockholm (POPs) Conventions.

13. 02. 2003 IPCS Geneva 4

Chemical Management Guide

Improve Chemical Management to Gain Cost Savings, Reduce Hazards and Improve Safety

13. 02. 2003 IPCS Geneva 5

The Chemical Management Guide was elaborated and published by GTZ-Pilot Project Chemical Safety in close cooperation with:

• The bilateral Indonesian-German Project ProduksiH which is counseling small and medium sized enterprises in the wide field of cleaner production and good housekeeping.

• The Pilot Programme for the Promotion of Environmental Management in the Private Sector of Developing Countries (P3U) who developed guides in the area of good housekeeping and environment-oriented cost management.

• German Federal Institute for Occupational Safety and Health.

• Tool 1 of the Guide is based wholly on the approach of the ILO Safe work chemical control Toolkit 2001, produced by the Geneva-based International Labour Organization working in collaboration with the International Occupational Hygiene Association (IOHA) and Health and Safety Executive (HSE) in the UK.

13. 02. 2003 IPCS Geneva 6

Objectives

Enabling the companies to:

• implement a framework for effective and preventive Chemical Management

• move in the direction of continuous improvement

It does not replace legal requirements!

13. 02. 2003 IPCS Geneva 7

Target groups

• companies where chemicals represent amajor portion of their running costs

• industry associations, business chambers

• management consultants

• institutions doing private sector promotion and/or environmental policy

13. 02. 2003 IPCS Geneva 8

Methodology

Tool for developing countries:

• Easy to understand and to apply

• Show incentives – make them take the bait

• Convincing that improvement is not expensive

• Demonstrate that international standards are achievable

• Show the benefit

13. 02. 2003 IPCS Geneva 9

Benefits

Triple win

Reducing production costs

Reducing environmental

impact

Improving worker health and safety

13. 02. 2003 IPCS Geneva 10

Purchase

Output in product Output as waste (solid, in the water, in

the air)

Flow of Chemicals in an Enterprise

Delivery

Storage

Handling and transfer

Processing

13. 02. 2003 IPCS Geneva 11

Methodology

Step by step implementation

Step 1 – Identify “hot spots”Step 2 – Make a comprehensive chemical

inventoryStep 3 – Make improvement continuously 5 Tools to help implement step 1 - 3

13. 02. 2003 IPCS Geneva 12

Step 1- Identify hot spots

Walk through your company and make observations

• Identify places of inefficient storage, handling, use and disposal of chemicals

• Identify particularly hazardous situations where potential harm could be reduced or prevented – spotting waste, losses and risks.

• Develop Action Plan

13. 02. 2003 IPCS Geneva 13

Mapping out of hot spots

Stored Chemicals

Transport and Handling of Chemicals

Processing of Chemicals

Output of Chemicals

Ground-Plan of the company

Office Area

Chemicals in Waste Water

chemicals in waste bins

Main Storage of Chemicals

Transport Area of Chemicals

old containersof chemicals

Chemicals stored at Working Place

Filling and bottling of chemicals

Production Area

Storage Area

Chemicals in the Production Process

Chemicals stored

Courtyard

Chemicals Delivery Area

13. 02. 2003 IPCS Geneva 14

Action Plan

Action Responsible Time Frame Remarks Results

13. 02. 2003 IPCS Geneva 15

General observations from test

implementation in five companies

Leather tannery, paint manufacturer, textile mills, textile dyeing, towel manufacturer:

– powdery dyestuffs should be replaced with granular or liquid dyestuff

– drums containing solvents should be covered– appropriate tools and protection gear should be provided to

workers – only products should be purchased by the companies, which

are properly labeled, transfer containers within the production process should be labeled also.

– companies should insist on provision of MSDS.

13. 02. 2003 IPCS Geneva 16

Chemicals stored in production area

13. 02. 2003 IPCS Geneva 17

Smooth and shiny leather tannery

Tannery

Producing leather for shoes and bags, for local and export market

Family business

Approx. 60 people in one shift

13. 02. 2003 IPCS Geneva 18

Smooth and shiny

Identified HOT SPOTS and priorities within the Action Plan

1. Repair leaking roof in the beam house2. Keep only the materials needed for daily use in the

production3. Create central storage area for dyestuffs with proper

management4. Stop selling green flashings for reuse in padang5. Improve handling of dyestuffs and hazardous chemicals6. Improve safety standard in the lab7. Avoid that chemical containers are used for bathing and

drinking water for workers8. …..

13. 02. 2003 IPCS Geneva 19

Cuttings of flashings are sold to restaurants to make crispy pork skin

13. 02. 2003 IPCS Geneva 20

Green flashings sold for making of crispy pork skin

13. 02. 2003 IPCS Geneva 21

Blue Velvet Success Story

Blue Velvet Textile Company• family-run company in Bandung, Indonesia

established since 1978,• employing 185 people working on 3 shifts per

day, • operates as a job shop, dyeing and printing

polyester and produces rayon, • production is destined for both local and export

markets.

13. 02. 2003 IPCS Geneva 22

Blue Velvet Success Story

Main recommendations from applying theChemical Management Guide:

1. Reduce waste of dyestuffs in sampling2. Improve handling of substances in the emulsion kitchen

to avoid losses, expiry, and contamination3. Identify substances that are particularly hazardous and

look for substitutes4. Remove chemicals not in immediate use from the

working areas of the factory as much as possible5. Ensure each department has a complete stock list

13. 02. 2003 IPCS Geneva 23

Action Plan Recommendation 1

Actions Taken Benefits Achieved

A smaller container (25 litres) is now being used to hold waste water from the dyestuff sampling so it can be collected and mixed back into the relevant process each week instead of keeping materials for 2 months in a larger container where the quality of the dye was being deteriorated.

Economic: The company reduced purchase costs by reusing more waste dye instead of using new dye in the Laboratory sampling process.Environmental: Less waste dye is being disposed of because more of the material is being reused.Workers health and safety: Smaller containers are easier and safer to handle

A sponge is now being used to clean dyestuff from screens instead of washing off this material with a high pressure hose into the drainage system.

Economic: Costs for purchasing water and cleaning wastewater were reduced. The company obtained savings of Rp. 400’000/month (Rp. 7.2 million/year) from this action. (1000 Rp. = aprox. 1 €)Environmental: The pollution load of waste water has been reduced.Workers health and safety: not relevant

13. 02. 2003 IPCS Geneva 24

Action Plan Recommendation 2

Actions Taken Benefits Achieved

The company improved its storage and handling of powder materials in the emulsion kitchen.

Economic: The company calculates it has obtained savings on chemical purchases. 25% of old stock (cotton dyestuffs) have been sold.

Environmental: Less chemicals are being wasted and need to be disposed of.

Workers health & safety: The health of workers is being protected by using appropriate transfer tools and personal protection equipment in handling powdery chemicals.

The company asked its supplier to provide glue in a plastic container instead of a can as this would be easier to open and close and avoid that the contents are exposed to air and deteriorate.

Economic: Glue losses were estimated to be in the range of 10%, representing Rp.25’000/can. The company has been able to reduce glue losses through this action.

Environmental: Less glue is wasted that must be disposed of in landfill.

Workers health & safety: Less inhalation of solvents, which can cause health problems.

13. 02. 2003 IPCS Geneva 25

Action Plan Recommendation 3

Actions Taken Benefits Achieved

The company contacted the supplier of an azo-dyestuff to request information about the contents of the chemical and availability of substitutes

Economic: The company can avoid that its products are rejected by international customers; assure compliance (e.g. with Öko-Tex standard).

Environmental: Reduced use of azo-dyestuffs that are very hazardous and banned for use.

Workers health & safety: Workers have to handle less materials being a risk for their health.

13. 02. 2003 IPCS Geneva 26

Action Plan Recommendation 4

Actions Taken Benefits Achieved

Ultrosol B, Salts, and other materials were removed from the production area

Economic: The company reduced costs for purchasing chemicals.

Environmental: Less material is being deteriorated in the hot & humid factory area, requiring disposal.

Worker health & safety: The removal of flammable materials from sources of ignition prevents explosion, accident, and injury.

13. 02. 2003 IPCS Geneva 27

Step 2 –

Make a comprehensive chemical inventory

13. 02. 2003 IPCS Geneva 28

Smooth and shiny inventory

No Chemi-cal name

MS

DS

Amount on hand

Scale of use

R-phrase, hazard band safety information

Notes about handling,

use storage conditions

87 Calcium hydro-xide (lime)

no Stored by drums

Use 80 kg/day

R 34 causes burns, corrosive

S 25, 36/27/39, 45

Store in cool dry place in tightly closed container.

Keep away from water

Use only in a chemical fume hood wearing safety goggles, Adequate ventilation is required.

13. 02. 2003 IPCS Geneva 29

Smooth and shiny inventory

Benefits from the inventory:

- Provides information on the danger and risk of chemicals- Enables the companies to search for replacements – less

dangerous and/or less costly materials- Gives possibility to monitor the use of the products –

improvement of efficiency in material utilization- Ensures proper management within the company,

dangerous chemicals can be treated appropriately.

13. 02. 2003 IPCS Geneva 30

Step 3 – Make improvement continuously

• Continue inventory and implementation of improvements• Replace dangerous chemicals for less toxic ones• Evaluate actions undertaken to determine if the set of

objectives have been achieved• Communicate and reward results• Monitor results to ensure that improvements are

maintained• Establish new target and areas for action in order to

make further improvements in the company’s operations.…

13. 02. 2003 IPCS Geneva 31

Tools to help you achieve steps 1, 2 and 3

1. Basic concepts for doing risk assessment

2. Description of control approaches

3. Using MSDS

4. Risk Phrases for hazardous substances

5. Safety Phrases for hazardous substances

6. Symbols used for labeling hazardous substances

13. 02. 2003 IPCS Geneva 32

Further activities

Training in Indonesia in March 03 in 3 areas (Semerang, Yogyakarta, Jakarta)

Training in Argentina in Mai 03 (Superintendencia de la proteccion del trabajador)

Training in Vietnam in October 03 – counterparts of experts from the German Development Service.

13. 02. 2003 IPCS Geneva 33

• The Chemical Management Guide is available in different languages:

• English

• Bahasa Indonesia

• Spanish (in process)

• French (in process)

13. 02. 2003 IPCS Geneva 34

Mixing of dyestuffs without protection