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1 CP Basics

Cleaner production
Considers your
Technologies
Employees
Raw materials
Processes
Emissions
Partners and
Products

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1 CP Basics

Elements of a CP-project
Data collection

Mass flow
Energy flow
Costs and safety

Reflection:
Where and why do we generate waste?

Option generation
Feasibility
Implementation
Controlling, continuation,
EMS

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1 CP Basics

Common waste treatment:

Waste is generated!
Whats that got to do with me?

Cleaner production:
Waste is generated!
Where does it come from?

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MATERIAL
Raw material,
process
material, other
material

ENERGY CARRIERS
Fuels, e.g.
gas, oil, coal

ENERGY
Mass free, e.g.
electricity or
district heating

OBSERVED
SYSTEM

1 CP Basics

PRODUCTS
Primary and
secondary

MATERIAL EMISSIONS
Solid waste,
gases,
wastewater

ENERGETIC
EMISSIONS
Waste heat,
noise

1 CP Basics

Slides
No

Waste or liquid or gaseous

emissions

Waste water

Spent grain (wet)

Annual
quantity

Unit

180,000

5,000

Purchasing cost Disposal cost

Total cost

10

2,880,000

around 800

-350

-1,750,000
(2,250,000)

Malt dust

447

4,000

1,788,000

Waste barley

220

4,000

880,000

Bottoms

30

250

7,500

Glass/broken glass

92

2,400

350

253,000

Plastic containers

18

10,000

2,000

216,000

Labels (wet)

50

30/1000 pcs

600

3,600,000
30,000

Cardboard / paper

35

5,000

175,000

10

Wood pallets

24

6,000

40

144,960

11

Plastic film

1.5

22,000

4,500

39,750

12

Industrial waste

104

800

83,200

13

Diatomaceous earth

45

8,000

930

401,850

14

Waste from maintenance,

200

kg

11

2,200

greasy
15

Contents of oil separator

3,200

kg

2.8

8,960

16

Waste oil

1,000

kg

50

52,000

17

Waste paints

50

kg

100

15

5,750

18

Fluorescent lamps

20

kg

120

12

2,640

19

Accumulators

25

kg

70

2.8

1,820

20

Waste gas, steam boiler

1,000,000

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1 CP Basics

Reasons for an environmental team

Because there are many different departments/machines in a
company, it is difficult to get the necessary overview and the
detailed technological knowledge.
Because there are motivated and competent employees in a
company.
Because as a TEAM with a common goal it is possible to work
more efficiently than a lone ranger.

Gather people from differnet departments:

production, maintenance, technology, purchasing, management,
quality, accounting, research and development, environment, health
and safety, legal branch, etc.

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1 CP Basics

Material flow analysis

Sankey-diagram: www.sankeyeditor.net

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1 CP Basics

Material flow analysis

Detailed description of the
material and energy use

Which waste and emission

streams are generated?
Which raw materials are lost?
Where and why does this happen?
Where are the weak points?
Where are potentials for improvement?
Which materials can be reused?

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Within the production

process, there are
many points where
materials and energy
are lost.

These points are also

environmental and
economic weak points.

A material flow
analysis identifies the
points where materials
are lost and their
amount.

1 CP Basics

Slides

A comparison with the

best available
technology shows
process weaknesses.
The material flow
analysis facilitates the
evaluation of the
"production costs" of
waste and emissions.
Eco-efficiency:
the best use of materials
reduces emissions.

1 CP Basics

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1 CP Basics

Strategies for cleaner production

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1 CP Basics

Product change
Substitute the product
Increase the product life-time
Change the materials
Change the product design
Use recycled materials
Avoid critical components

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1 CP Basics

Good housekeeping
Improve information
Change dosage/concentration
Increase the utilization of process capacities
Check cleaning and maintenance period

Foster standardization/automation
Improve purchasing, storage and distribution
Carry out a material flow analysis

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1 CP Basics

Waste logistics
Separation of waste and wastewater to
Set up closed cycles
Facilitate recovery and re-utilization
Minimize quantities of hazardous waste
Minimize disposal costs
Minimize cleaning expenses
(wastewater, exhaust gases, etc.)

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1 CP Basics

Technological modification
Substitute thermo-chemical processes by mechanical
alternatives
Use countercurrent cascades instead of single-static
rinse techniques
Manage separate waste and wastewater streams
Improve process conditions
Foster recovery and reuse of materials
Increase life time of chemicals/materials
Reduce the infiltration of impurities
Ensure airtight sealing of equipment

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1 CP Basics

Energy efficiency

Typical areas of improvement

Cooling/refrigeration
Heating
Compressed air
Insulation
Heat recovery
Separation processes
Lighting
...

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1 CP Basics

Internal recycling

Reuse materials (solvents, etc.)

Reuse materials for different purposes (paper,
solvents for lower-quality use, e.g. pre-cleaning,
etc.)
Close internal loops (water)
Use returnable systems (packaging materials)

Reclaim materials with high value

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1 CP Basics

ECOPROFIT Graz 2000

Realized and planned options

Product modification
5%
Waste treatment
3%

Others
6%

Organizational
changes
29%

External recycling
6%

Internal recycling
4%

Technological
modification
22%

Good housekeeping
18%
Change of raw
material
7%

In total 594 options, thereof:

60 %; 355 = realized options 2000
40 %; 240 = planned options 2001

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Anodizing company
Use of spray rinses
Reconstruction of water
pipes
Longer drag-out time
Daily check
Reduction in water
consumption by 46%
(14,000 m)

1 CP Basics

1 CP Basics

Slides

Specific water consumption

of an anodizing company
1.500

l/m

1.000

500

0
specific water consumption

1993

94

95

96

97

98

99

2000

1.263

1.273

919

600

392

425

400

400

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1 CP Basics

Car repair shop

Installation of an ultrafiltration unit

Modified cleaning equipment
Saving of washing agent by 76 %, of water by 80 %