1. 1 ETIV - EMAS Technical Implementation and Verification 1 Case study: Implementation of EMAS in the Ceramic industry Eng. Marisa Almeida - CTCV CTCV - Coimbra Fevereiro.2005 Case study Implementation of EMAS in the Ceramic industry

2. 2 ETIV - EMAS Technical Implementation and Verification 2 Issues: 1. Structure of the ceramic study-case Ceramic process Development of an EMS according to EMAS II Enviromental improvement - photos Main difficulties - photos 2. Training material 3. ETIV Main difficulties Case study Implementation of EMAS in the Ceramic industry

3. 3 ETIV - EMAS Technical Implementation and Verification 3 Description of ceramic location Case study Implementation of EMAS in the Ceramic industry

4. 4 ETIV - EMAS Technical Implementation and Verification 4 Analyses of case-study: 1. Study case structure: Part 1 – Description of the company: Maronagrés – ceramic tiles company – certified by ISO9001:2000 Sanindusa 2 – Sanitaryware company; Brief summary of the case study; Driving forces and Benefits of EMAS Case study Implementation of EMAS in the Ceramic industry

5. 5 ETIV - EMAS Technical Implementation and Verification 5 Analyses of case-study: 1. Study case structure: Part 2 – Case studies : PDCA MODEL: Plan- Do- Check-Act Integrated system - process approach PLAN Collection of data on the organisation (design information, environmental information, raw material/production information, economic and other); Environmental Review Diagnostic; Environmental policy (A.2); Significant environmental aspects (A.3.1); Legal and other requirements (A.3.2); Objectives and targets (A.3.3); Environmental management program (A.3.4); Case study Implementation of EMAS in the Ceramic industry

6. 6 ETIV - EMAS Technical Implementation and Verification 6 Analyses of case-study: 1. Study case structure: Part 2 – Case studies : Implementation and operation (Do): Definition of structure and responsibility and provide resources (see A.4.1); Training, awareness and competence (see A.4.2);; Establish internal and external communication (see A.4.3); Create and maintain EMS documents (see A.4.4); Documentation control (see A.4.5); Establish and maintain operational control (see A.4.6); Emergency preparedness and response (see A.4.7). Checking and corrective action (Check): Monitoring and measurement (see A.5.1); Non-conformance and corrective and preventive actions (see 4.5.2); Manage Records (see 4.5.3); Conduct periodic EMS audits (see A.5.4). Management Review (Act): conduct Management review (see A.6); identify areas for improvement; environmental declaration; Case study Implementation of EMAS in the Ceramic industry

7. 7 ETIV - EMAS Technical Implementation and Verification 7 Analyses of case-study: 1. Study case structure: Part 2 – Case studies : ISSUES TO BE ADDRESSED BY ORGANISATIONS IMPLEMENTING EMAS Legal compliance Performance External communication and relations Employee involvement Part 3 – Evaluation and conclusions Fundamental difficulties found; Experience collected by the company during EMAS implementation; Environmental improvements achieved (results, benefits); Photos of the environmental achievements of the Company; Conclusions Case study Implementation of EMAS in the Ceramic industry

8. 8 ETIV - EMAS Technical Implementation and Verification 8 Analyses of case-study: 2. Ceramic process description Case study Implementation of EMAS in the Ceramic industry

9. 9 ETIV - EMAS Technical Implementation and Verification 9 2. Maronagrés ceramic process Case study Implementation of EMAS in the Ceramic industry

10. 10 ETIV - EMAS Technical Implementation and Verification 10 2. Sanindusa 2 ceramic process

11. 11 ETIV - EMAS Technical Implementation and Verification 11 Implementation of EMS - EMAS Environmental Review Diagnostic data on the organization (location, production information, raw materials and energy input); environmental information: Local conditions: geological, soil, atmospheric Consumption data: raw material, water, energy Emission data: emissions to air, emission to water, emission to land – wastes, noise; List of legislation and other requirement applicable to the ceramic industry; Planned activities (summary) Case study Implementation of EMAS in the Ceramic industry

12. 12 ETIV - EMAS Technical Implementation and Verification 12 Analyses of case-study: A.2 Environmental policy Maronagrés quality and environmental policy states commitments to: Continual improvement of product, process and services with a minimal adverse environmental impact; environmental legal requirements and other environmental requirements to which the organization subscribes; prevent pollution; efficient use of resources, avoid and minimized (and valorization) the waste, gaseous emissions and noise control; continual improvement through the implementation of the best available technologies (BAT) adequate to its environmental impacts; employees qualification and motivation; documented, implemented, maintained and communicated, reviewed the policy, objectives and other information regarding the Management System (Q&E) to all employees and other interested parties; involve interested parties like suppliers, clients and local community in the Management System (quality and environment) Case study Implementation of EMAS in the Ceramic industry

13. 13 ETIV - EMAS Technical Implementation and Verification 13 A.2 Environmental policy: * Integrated with quality and heath and safety; * focus on continual improvement of product, process and services with a minimal adverse environmental * environmental legal requirements and other * best available technologies (BAT)

14. 14 ETIV - EMAS Technical Implementation and Verification 14 Analyses of case-study: 3. Significant Environmental aspects and impacts procedure Case study Implementation of EMAS in the Ceramic industry

15. 15 ETIV - EMAS Technical Implementation and Verification 15 Analyses of case-study: Case study Implementation of EMAS in the Ceramic industry

16. 16 ETIV - EMAS Technical Implementation and Verification 16 Environmental aspects: Raw Material Usage: ceramic products are manufactured mainly from natural raw materials (clays, sands, feldspars, limestone etc) Energy consumption: high – big consummer Emissions to Air: represent the main environmental concern of the industry: fluorine and heavy metals and VOC and combustion gases Emissions to Water: are mainly insoluble particulate matter derived from material processing – so can be separated by settling/filtration (often for re-use). Waste: slurry from wastewater treatment, scrap, dangerous waste – few: waste oil, etc... Case study Implementation of EMAS in the Ceramic industry

17. 17 ETIV - EMAS Technical Implementation and Verification 17 Analyses of case-study: A.3.1 Significant Environmental aspects and impacts procedure Conditions: normal, abnormal (shut-down, start-up and maintenance) and emergency past, on-going and planned activities, Criteria: significant environmental impacts according to requirement in Annex VI(6) of EMAS II: Size (scale), severity and frequecy of the env. aspects Fragillity of enviroment Importance of stakeholders Legal issues: Enviromental legislation or other requeriments Case study Implementation of EMAS in the Ceramic industry

18. 18 ETIV - EMAS Technical Implementation and Verification 18 Environmental aspects procedure: A.3.1 Maronagr é s Procedure Case study Implementation of EMAS in the Ceramic industry

19. 19 ETIV - EMAS Technical Implementation and Verification 19 Environmental aspects procedure: A.3.1 Maronagr é s Env. aspects Case study Implementation of EMAS in the Ceramic industry

20. 20 ETIV - EMAS Technical Implementation and Verification 20 A.3.1 Maronagrés Env. aspects : Classification of environment aspects The significant environment degree (S) is made by: S = F (fragility) * P (probability) * G (G=gravity = severity*scale) * C (control) * I (Importance of stakeholders) If S < 405, the impact is classified as significant or if there are legal issues applicable. Case study Implementation of EMAS in the Ceramic industry

21. 21 ETIV - EMAS Technical Implementation and Verification 21 Environmental aspects procedure: A.3.1 Sanindusa 2 Procedure Case study Implementation of EMAS in the Ceramic industry

22. 22 ETIV - EMAS Technical Implementation and Verification 22 Environmental aspects procedure: Direct environmental aspects include: emissions to air (from chimneys);s releases to water (domestic and industrial); production and treatment of wastes; use of natural resources and raw materials (including water, natural resources, electric energy and fuel); local issues (noise, odor, dust, visual appearance, etc.); transport issues (both for goods and services and employees); risks of environmental accidents and impacts arising (or likely), as consequences of incidents, accidents and pot. emergency situations; Indirect environmental aspects include: product related issues (design, development, packaging, transportation, use and waste recovery/disposal); the environmental performance and practices of contractors, subcontractors and suppliers. Case study Implementation of EMAS in the Ceramic industry

23. 23 ETIV - EMAS Technical Implementation and Verification 23 Environmental aspects procedure: Case study Implementation of EMAS in the Ceramic industry

24. 24 ETIV - EMAS Technical Implementation and Verification 24 Maronagrés significant env. aspects: A.3.2 Env. aspects Case study Implementation of EMAS in the Ceramic industry

25. 25 ETIV - EMAS Technical Implementation and Verification 25 Sanindusa 2 significant env. aspects: A.3.2 Case study Implementation of EMAS in the Ceramic industry

26. 26 ETIV - EMAS Technical Implementation and Verification 26 Sanindusa 2 significant env. aspects: A.3.2 Case study Implementation of EMAS in the Ceramic industry

27. 27 ETIV - EMAS Technical Implementation and Verification 27 Sanindusa 2 significant env. aspects: A.3.2 Case study Implementation of EMAS in the Ceramic industry

28. 28 ETIV - EMAS Technical Implementation and Verification 28 Legal requirements: Analyses of case-study 4.3.2 Legal requirements Software system: mydox (developed by CTCV) – compilation of Portuguese and European legislation with an automatic up-date in 15 days; Sites: www.dre.pt, www.ipq.pt and www.diramb.gov.pt, www.eudor.com permits, licenses or other forms of authorization; register of applicable environmental legal requirements. Case study Implementation of EMAS in the Ceramic industry

29. 29 ETIV - EMAS Technical Implementation and Verification 29 Objectives: Analyses of case-study A.3.3/4 Objectives, targets and programme(s) Case study Implementation of EMAS in the Ceramic industry

30. 30 ETIV - EMAS Technical Implementation and Verification 30 Maronagrés Objectives, targets and programme(s): Case study Implementation of EMAS in the Ceramic industry

31. 31 ETIV - EMAS Technical Implementation and Verification 31 Sanindusa 2- Objectives, targets and programme(s): Case study Implementation of EMAS in the Ceramic industry

32. 32 ETIV - EMAS Technical Implementation and Verification 32 A.4.1 Structure and responsability - Maronagr é s: integrated in Quality The top management was appointed one of the top management directors as a Management Representative for the coordination of the Quality and Environmental Management System (QEMS) The functions of the Director of Quality and Environment are, among others: to keep inform the Management Representative about the performance, current status and progress of the QEMS; to communicate with external entities related to the QEMS; to collected information to allow management to carry out the management review process. Case study Implementation of EMAS in the Ceramic industry

33. 33 ETIV - EMAS Technical Implementation and Verification 33 A.4.1 Structure and responsability - The resource needed to implement and maintain the EMS, have considered: human resources (see organizational structure); infrastructure technology and Technical resources; financial resources Case study Implementation of EMAS in the Ceramic industry

34. 34 ETIV - EMAS Technical Implementation and Verification 34 A.4.1 Structure and responsability - Sanindusa 2 : integrated with Quality, health and safety The top management was appointed one of the top management administrators as a Management Representative for the coordination of the Quality, Environmental and safety and heath Management System (QESHMS). The Environment responsible as the ultimately responsible for the environmental system Case study Implementation of EMAS in the Ceramic industry

35. 35 ETIV - EMAS Technical Implementation and Verification 35 A.4.2 Training, awareness and competence - Training, awareness and competence - Maronagr é s: integrated in Quality Sanindusa 2 : integrated with Quality, health and safety Case study Implementation of EMAS in the Ceramic industry

36. 36 ETIV - EMAS Technical Implementation and Verification 36 A.4.3 Communication Communication process Case study Implementation of EMAS in the Ceramic industry

37. 37 ETIV - EMAS Technical Implementation and Verification 37 Analyses of case-study : A.4.3 Communication Maronagr é s: integrated in Quality, Plan, Measuring, etc... Sanindusa 2: procedure - integrated with Quality, health and safety Internal communication: Internal communication – placards (see examples in annex ?); Minutes of meetings; Training register; Internal inquires (satisfaction) electronic mail, ·Intranet; Information brochures (see examples in annex ?). External communication medium types: Letter; Fax; Telephone Email; Internet; Visit to the ceramic industries Case study Implementation of EMAS in the Ceramic industry

38. 38 ETIV - EMAS Technical Implementation and Verification 38 Documentation – Process aproach Case study Implementation of EMAS in the Ceramic industry

39. 39 ETIV - EMAS Technical Implementation and Verification 39 Documentation A.4.4. Documentation – integrated with Quality and health and safety: 1. Manual 2. Funcional procedures 3. Operative procedures –work instructions 4. Records Funcional procedures: Identifying and classification of Environmental Aspects; Legal and other environmental requirements; Competence, training and awareness - Q Communication - Q Emergency preparedness and response Monitoring and measurement Nonconformity, corrective and preventive actions - Q Internal audit – Q – adictional requeriments - programme Management Review - Q Case study Implementation of EMAS in the Ceramic industry

40. 40 ETIV - EMAS Technical Implementation and Verification 40 Documentation (2): A.4.5 Document control the control document procedure (GSP001) includes the documentation structure including the titles, code numbers, dates, version, revisions, revision history or authority, approval, pages and total pages. The control is made to documentation from internal and external sources. Example of an informatics' program for documentation management – ISI 9000 Case study Implementation of EMAS in the Ceramic industry

41. 41 ETIV - EMAS Technical Implementation and Verification 41 A.4.6. Operational control A.4.6. Operational control – procedures and work instructions: Maronagrés: integrated with previous quality work instructions (including purschasing) through the process activities; Specific procedures: Waste management; waterwater Treatment facility; Gaseous emissions treatment facility - fluorine; Subcontracting; Chemical substances Case study Implementation of EMAS in the Ceramic industry

42. 42 ETIV - EMAS Technical Implementation and Verification 42 A.4.6 Operational control: Sanindusa 2: two level approach : overall and specific procedure for operational control – GAP004 Specific procedures: GAP007 – Gestão de resíduos GAP008 – Gestão de efluentes gasosos (in annex) GAP009 – Gestão de efluentes líquidos GAE001 – Requisitos ambientais para compras – environmental requirements in purchasing GAI001 – Preenchimento das Guias de acompanhamento de resíduos; GAI002 – controlo operacional da secção de preparação de vidro; GAI003 – controlo operacional da secção de olaria; GAI004 – controlo operacional da secção de secagem; GAI005 – controlo operacional da secção de vidragem; GAI006 – controlo operacional da secção de fornos; GAI007 – controlo operacional dos resíduos de caco cozido; GAI008 – Controlo Operacional da Manutenção – operational control in maintenance GAI009 - Controlo Operacional da ETA e ETAR – operational control in ETA (water treatment facility) and ETAR (wasterwater facility); GAI010 – controlo operacional do laboratório GAI011 – controlo operacional do armazém; GAI012 – controlo operacional avaliação de questionários; GAI013 – controlo operacional de serviços administrativos; GAI014 – Controlo das operações de trasfega – operational control on handling and transport ; Subcontracting; Case study Implementation of EMAS in the Ceramic industry

43. 43 ETIV - EMAS Technical Implementation and Verification 43 A.4.7 - Emergency 4.4.7 Emergency preparedness and response Identified emergency situation include: Untreated wastewater discharges; Chemical substances discharges including (products for wastewater treatment, solvents, glazes); Fuel or Oil discharges; * Natural gas release; Particulates emissions (diffuse emissions); Firing; * Explosion; natural disasters (e.g. flooding, earthquakes) Case study Implementation of EMAS in the Ceramic industry

44. 44 ETIV - EMAS Technical Implementation and Verification 44 A.4.7 Emergency The emergency preparedness and response Plan include: general description of ceramic industry; location of the ceramic industry including a schematic map of the facility, evacuation routes, location of environmental emergency equipment, and assembly points; Identification of potentials environmental accidents and emergencies; list of hazardous substances and quantities; emergency organization and responsibilitie; action procedure: written procedures to mitigation and response actions to be taken to solve different types of emergency situations or accidents. alarms; internal and external communication (e.g. neighborhood); distribution: list to whom the plan is distributed and the responsible for distribution; annex. Case study Implementation of EMAS in the Ceramic industry

45. 45 ETIV - EMAS Technical Implementation and Verification 45 A.5.1 Monitoring and measuring The environmental key characteristics are: Waste management; Gaseous emissions; Water consumption; Wastewater discharges (industrial and domestic); Noise; Energy. Case study Implementation of EMAS in the Ceramic industry

46. 46 ETIV - EMAS Technical Implementation and Verification 46 A.5.1 Monitoring and measuring Example of monitoring plan in Maronagrés Case study Implementation of EMAS in the Ceramic industry

47. 47 ETIV - EMAS Technical Implementation and Verification 47 A. 5.1 Monitoring and measuring Example of monitoring plan in Sanindusa 2 Case study Implementation of EMAS in the Ceramic industry

48. 48 ETIV - EMAS Technical Implementation and Verification 48 NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE ACTION Fonte: CTCV Examples of nonconformities can include: Gaseous emissions, noise, water, wastewater or energy reduction targets are not achieved; Operating criteria (e.g. permitted limits) are not met; Results from audits; Records analysis; Legal requirement and other analysis; Complains from interested parties; Records required of progress on objectives and targets are not being kept; Responsibilities are not assigned as required for an important function of the EMS, such as emergency response; Case study Implementation of EMAS in the Ceramic industry

49. 49 ETIV - EMAS Technical Implementation and Verification 49 NONCONFORMANCE Fonte: CTCV NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE ACTION Case study Implementation of EMAS in the Ceramic industry

50. 50 ETIV - EMAS Technical Implementation and Verification 50 RECORDS Maronagrés – informatics treatment Some examples of environmental records include: a)Information on environmental aspects of the ceramic industry; b)Information on environmental indicator performance; c)evidence of accomplishment of objectives/targets; d)Information on applicable environmental laws and regulations; e)permits, licenses or other forms of legal authorization; f)Monitoring and measuring data; g)Calibration and maintenance activities of the equipment; h)Training records; i)Decisions regarding external communication; j)Information regarding contractors and suppliers; k)results of operational controls; l)details of nonconformities and corrective and preventive actions; m)Audit results; n)Results of management reviews. Fonte: CTCV Case study Implementation of EMAS in the Ceramic industry

51. 51 ETIV - EMAS Technical Implementation and Verification 51 EMS AUDIT EMS Audit integrated: Quality – Maronagrés Quality and heath safety – Sanindusa 2 Conducting the audit include several techniques and tools like ISO19011:2003, checklist, observations, documents consulted. The internal EMS audits can be carried out by personnel from the ceramic company, by external auditors (consultant) or by a combination of both Fonte: CTCV Case study Implementation of EMAS in the Ceramic industry

52. 52 ETIV - EMAS Technical Implementation and Verification 52 MANAGEMENT REVIEW Management review integrated: Quality – Maronagrés Quality and heath safety – Sanindusa 2 The review cover the environmental aspects of activities, products and services that are within the scope of the EMS. The EMS of both ceramic industries should be reviewed at least once a year in order to guarantee suitability, adequacy, and effectiveness of the system. It is also analyse its integration with the overall management system and its relationship to the current and anticipated regulatory legislations Fonte: CTCV Case study Implementation of EMAS in the Ceramic industry

53. 53 ETIV - EMAS Technical Implementation and Verification 53 Environmental improvements achieved Results and benefits: reduction of the amounts of energy consumed – process optimization; Gaseous emissions treatment - fluorine; Adopt of BAT (best available tecniques) Noise reduction; Natural gas - optimization. Fonte: CTCV Case study Implementation of EMAS in the Ceramic industry

54. 54 ETIV - EMAS Technical Implementation and Verification 54 Environmental improvements achieved Results and benefits: reduction of the amounts of energy consumed – process optimization; Adopt of BAT (best available tecniques) Use of natural gas in substitution of propane gas (GPL), provided by LNG Storage tank Fonte: CTCV Case study Implementation of EMAS in the Ceramic industry

55. 55 ETIV - EMAS Technical Implementation and Verification 55 Environmental improvements achieved Fonte: CTCV selective collection of wastes produced; Waste selective area; Waste valorisation; Rehabilitation of watewater facility toner cartridges and ink cartridges container; Chemical substances container; Minization of environmental accidents Case study Implementation of EMAS in the Ceramic industry

56. 56 ETIV - EMAS Technical Implementation and Verification 56 Main Difficulties found in EMAS: Fonte: CTCV The Portuguese legal requirement on gaseous emissions: monitoring all chimneys, chimneys high, etc... The waste final manager – not all legally authorized The environmental noise, specially in the case of Maronagrés, has the surrounding human house growth after the Maronagrés facilities installations Changing old practices … Case study Implementation of EMAS in the Ceramic industry