A Contribution of the Cleaner Production Program To

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A contribution of the Cleaner Production Program to

the ISO 14001 Management System: a case study in themetal-mechanic sector

Fernando Magnani CerveliniNMHG-Brasil

[email protected]@vivax.com.br

Maria Tereza Saraiva SouzaUninove

[email protected]

ABSTRACT: The aim of this work is to identify the contributions of the Cleaner Production Program to the Environ-mental Management Sstem cetie to ISO 14000. The esults of the eseach inicate that the poceue stana-ization emane b nomalization leas the compan to aopt envionmentall aequate poceues; besies, theimplementation of the Cleane Pouction Pogam acts as a complementa tool in the EMS, with a view to impovingenvionmental pefomance.

KEy WOrdS: ISO 14000; Environmental Management System; Cleaner Production

1. INTRODUCTION

Nowaas, envionmental tools can eoient thepouction pocess of goos an sevices. An En-vionmental Management Sstem cetie to ISO14001 is egae as one of the most aequate in-stuments to impove business pefomance anexpansion. Some stuies, howeve, show that thecreation of the Environmental Management Systemcetie to ISO 14001 oes not guaantee a changetowas geate envionmental esponsibilit in thepouction sstem.

Fo inusties in eveloping counties to pomote

sustainable evelopment an face competition inthe global maket, much moe is neee than theobtainment of ISO 14000 cetication. It is impo-tant that poucts, sevices an pouction pat-terns be revised with a view to cleaner and moreecient pouction, with lowe cost an beequalit poucts.

The pesupposition that oiente this eseach wasthat an Environmental Management System basedon ISO 14000 noms complies with the legislation;howeve, thee ae oppotunities fo impovement

in the sstem, with the insetion of Cleane Pouc-tion Pogam concepts.

With this scenaio in min, the aim of this wok wasto identify the contributions of the Cleaner Produc-tion Program to an Environmental Management Sys-tem – EMS – cetie to ISO 14001, aiming at the im-povement of envionmental conuct in goos ansevice povie oganizations. The unit of analsisfor the study was the Environmental ManagementSstem – EMS – cetie to ISO 14001 of a metal-mechanic secto compan.

2. RESEARCH METHODOLOGY

This eseach aopte the methoolog of singlecase stu. The compan chosen is a leaing mul-tinational compan in the metal mechanic secto,manufactuing equipment fo moving goos, withthe Envionmental Management Sstem cetie toISO 14001 in 2002 an e-cetication in 2006.

Taking into consideration the factors mentioned b yin (2001), as egas the compan chosen anthe secto, the justication fo single case stu is

THE FLAGSHIP RESEARCH JOURNAL OF INTERNATIONAL CONFERENCEOF THE PRODUCTION AND OPERATIONS MANAGEMENT SOCIETYVolume 2• Numbe 1 • Janua - June 2009

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Cervelini, Fernando Magnani and Souza, Maria Tereza Saraiva: A contribution of the Cleaner Production Program to the ISO 14001

Management System: a case study in the metal-mechanic sectorJournal of Operations and Supply Chain Management 2 (1), pp 61 - 76, C International Conference of the Production and Operations Management Society62

the fact that it epesents a ecisive case, because itfulls the conitions equie to test the aims po-pose. It ceates the appopiate conitions fo thecompehension, the contestation o the conma-tion of the theo, an it is conucte as an into-uction to a etaile stu, with the utilization of

exploato mechanisms. Accoing to Siggelkow(2007), the cases stuies can be use in the contextof making a conceptual contibution to emplothem as illustration.

Vaious souces of evience wee use in this wok,allowing fo the evelopment of convegent lines ofinvestigation b means of a tiangulation pocess ofinfomation fom ieent ata souces (yin, 2001).The data collection instruments used were docu-ments, achive ecos, inteviews, iect an pa-ticipant obsevation.

The following ocuments fom the compan weeanalyzed: Environmental Management SystemManual; ocumente communication between thecompan an envionmental authoities; invest-ment chats fo envionmental maes; EuentTeatment Plant an inustial pocess opeationow chats; gaphics an tables with envionmen-tal inicatos; minutes of meetings petaining to theEnvionmental Management Sstem; envionmen-tal aspects an impact chats; waste managementpoceues; ocuments elate to the compan’s en-vionmental liabilities; questionnaies on envion-mental pactices fo supplies; Euent TeatmentPlant contol epots; sevice oes; aw mateialenties; wate use ccle; pouction pocess ocu-ments; envionmental management plan; envion-mental contol plan.

The records used were: Corrective Action and Preven-tive Action (CAPA); intenal poceue an wok in-stuctions; annotations of non-confomit envion-mental occurrences found by internal and externalauiting; waste estination contol chats; annota-tions of wate an electicit consumption.

With the bibliogaphical eseach as a base, it waspossible to elaboate a scheule fo the inteviews.The inteviews consiste of questions elate to theenvionmental sstem, an the aim was to analzepefomance an to ientif oppotunities fo im-povement in the compan’s Envionmental Man-agement Sstem cetie to ISO 14001. The inte-viewees wee the people iectl esponsible fo theadministration of the Environmental ManagementSstem: supevisos who took pat in the implemen-

tation of the Envionmental Management Sstem,sta in geneal an extenal envionmental consul-tants who help in the maintenance of the Envion-mental Management Sstem – 19 people in all. Thequestions wee sent peviousl so that intevieweescoul pepae the answes an seek fo infomation

they did not have at hand.Two ieent kins of iect obsevation, fomal aninfomal, wee use in this case stu. Fomal obse-vation implie paticipation in meetings petainingto the EMS. Infomall, waste stoage aeas, hanlingof poucts an waste, pollution souces an eu-ent euse wee obseve. Paticipant obsevation wasalso an instument in this stu, as the autho takespat in activities elate to EMS in the compan.

Triangulation was carried out making use of the re-sults obtaine in the inteviews, the analsis of oc-

uments and records in the Environmental Manage-ment Sstem achives, plus iect obsevation anpaticipant obsevation.

3.THEORETICAL BACKGROUND

The st manual on how to minimize inustial wastein manufactuing pocesses was publishe b theEnvironmental Protection Agency - US (EPA) in 1988.The secon manual was publishe in 1991 b twoUNO agencies: United Nations Environmental Program

(UNEP) an United Nations Industrial Development(UNIdO). The text Audit and Reduction Manual for In-dustrial Emissions and Wastes was ae in the con-text of the Cleane Pouction Pogam, to be use bpofessionals in the inustial secto, consultants angovenment authoities inteeste in impoving ela-tions between industry and the environment.

According to Centro Nacional de Tecnologias Limpas,CNTL/SENAI (the National Center for Clean Tech-nologies) the main objective of Cleane Pouctionis to eliminate o euce the emission of pollutants

in the envionment, while optimizing the use of awmateials, wate an eneg.

To Babiei (2004), Cleane Pouction is chaac-terized by actions that aim at reducing waste andemissions at the souce, theefoe pioit shoul begiven to measures that try to eliminate or minimizewaste, euents an emissions in the pouctionpocess wheeve the ae geneate.

Cleane Pouction actions ae given pioit ac-coing to the ow chat in gue 1.


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Management System: a case study in the metal-mechanic sectorJournal of Operations and Supply Chain Management 2 (1), pp 61 - 76, C International Conference of the Production and Operations Management Society 63

Figure 1. Cleaner production ow chart

Cleaner Production

Minimization of waste andemission

Level 1 Level 2

Reduce atsource

Internalrecycling

Modificationof product

Modificationin the process

Housekeeping Substitution ofraw materials

TechnologicalModification

Reuse of wasteand emission

Level 3

Externalrecycling

Biogenic cyles

Structure Materials

Souce: Cento Nacional e Tecnologias Limpas – CNTL/SENAI (2004)

It shoul be obseve that at Level 1: Reduction atsource , pioit is given to actions that aim at euc-ing the generation of waste and emissions at the gen-eating souce. When it is not possible to aopt themeasues suggeste at Level 1, moving on to Level 2,the aim is to optimize the intenal ccle of the com-pan with the euse of waste geneate, within thepocess itself o in anothe pocess in the compan.Level 3 comes into being when waste and emissionsgeneate cannot be euse in the same pouctionunit where they were generated.

Thus, options available fo Cleane Pouction must be analze an selecte with pioit being given,wheneve possible, to Level 1 altenatives (euctionat souce), followe b Level 2 actions (intenal ec-cling), with Level 3 (extenal eccling an biogenicccles) as a last esot.

Accoing to COrBETT (2001), The eect of iso14001 as an emissions euce weakene, while theeect powe of the envionmental management ss-tem to reduce emissions became stronger.

To Klassen (1993), b incluing both envionmen-tal an qualit factos in the new poucts anpocess, the continuous impovement ove the longtem is possible.

3.1 Comparing ISO 14001 and Cleaner Production

Cleane Pouction, when compae to ISO 14001,pesents the following avantages: a potential foeconomical solutions, with a euction in the amountof mateials an eneg use; scope fo innovationin the compan, as a esult of the evaluation of thepouction pocess; minimization of waste, eu-ents an emissions; euction of isks in the aeasof envionmental obligations an isposal of waste,since esponsibilit is assume fo the pouctionpocess as a whole; enition of iectives fo sus-tainable economic evelopment.

According to LaGrega et al. (1994), the conitioningfactos “technologies” an “poceues” must evolvetowas the composition of scenaios that ae moeenvionmentall aequate, as seen in Figue 2.


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Figure 2: Technologies e environmental procedures

PREVENTIONPREVENTION

Reduction

at source

Change in theproduct

Substituition of

the product.

Conservation of

the product.

Alteration in the

composition of

the product.

Control at

source

Change in the

process.

Regeneration

and use

Return to the

process.

Use as raw

material in a

different

process.

Recuperation

Recuperation of

the material.

Use as sub-

product or fuel.

Change of the

raw material

Change of the

technology

Recycling

END OF PIPEEND OF PIPE

Treatment

and disposal

Waste

treatment

Waste stock

Incineration

Final disposalGood

Pratices

CLEANER PRODUCTIONCLEANER PRODUCTION ISO 14001ISO 14001

Souce: LaGega et al, (1994)

Figue 2 pesents the evolution of technologies an poceues eecting the ieences in an EnvionmentalManagement Sstem that emplos peventive stategies, epesente b Cleane Pouction, o an EMS us-ing End of Pipe stategies, epesente b the sstem base on ISO 14000 noms.

LaGega’s oganization chat (gue 2) ma be useful in the enition of Cleane Pouction techniques to be aopte in the pouction pocess, since it pesents examples of measues to be taken an inications ofpioit oe (fom le to ight). Theefoe, the most esiable option is the aoption of “euction at souce”techniques, followe b intenal eccling, then extenal eccling an nall End of Pipe technologies, founin the last column on the ight (waste teatment an isposal).

Futao (1998) ams that both ISO 14001 an Cleane Pouction contibute towas impoving envionmentalconuct in oganizations that povie sevices an pouce goos, but ae ieent in thei objectives, metho-

ologies an tagets. To Cobe (2001), the ISO 14001 sstems is not bing the immeiate benets if the compangoal is euce the emission, but it must be analse if the custome equies an iso 14001 sstem

In Table 1, é oa stu compaing an Envionmental Management Sstem base on ISO 14001 é noms anCleane Pouction is pesente.


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Table 1: A comparison between EMSs: ISO 14001 x Cleaner Production

PARAMETERS/MANAGEMENT

TOOLSEMS BASED ON ISO 14001 NORM

EMS WITH CLEANER

PRODUCTION

Principles Not dened. Prevention of Pollution

Focus

Sistematization of information related

to aspects of production process: use

of techniques in general that may

minimize/treat waste.

Identication of generating source and

use of techniques to minimize waste

Object of CerticationEnvironmental Management System and

not environmental performance Not passible of certication

Costs

Associated mainly to:

Elaboration of procedures and generation

of the documentation required by ISO

14001 norm; use of techniques of

minimization / treatment of waste

Related to the adoption of measures

aiming at minimizing waste

Coverage

Systemic measures concerning:

Environmental Policies, Communication

with involved parties, Environmental

emergency plans etc.

Obs: Survey of environmental aspects

and e impacts focus on waste, but

encompassing less than Cleaner

Production

Measures aiming at reducing

consumption of energy, supplies and

raw materials, and minimization in the

generation of solid waste, liquid efuents

and atmospheric emissions.

Vision Integrated; continuous improvementIntegrated; continuous and incremental

improvement

Revision and Evaluation mechanism

By means of operational Control,

auditing and critical analysis, using

mostly indicators of an administrative

character

By means of constant analysis of

environmental performance indicators.

Refuse and industrial waste handling.

It privileges the process and controls

associated to the focuses in the End of

Pipe technologies and attendance to the

legislation.

Prevention of waste at source; limits

the use of landll sites; condemns a

indiscriminate incineration.

Directives Determined by local certication ofces. Use internacional standards

Applicability Greater in mid to large companiesAll companies, including small and

micro enterprises.

Souce: base on Kipestok, et al. (2002)

As obseve in Table 1, the focus of an EMS base on ISO 14001 noms is on infomation sstematization,with the aim of ientifing mechanisms use to manage envionmental aspects an impacts, without a peoc-cupation with the uneling iective pinciple.

Table 2 ma povie futhe oientation fo the insetion of Cleane Pouction concepts into an Envionmen-tal Management Sstem base on ISO 14001 noms.


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Table 2: A proposal for insertion of the Cleaner Production model into ISO 14001 requisites (2004).

ISO 14001 REQUISITES EMPHASIS/ MAIN APPROACH

4.2- Environmental PoliciesCommitment to Cleaner Production in the shape of prevention of

Pollution.

4.3.1- Environmental Aspects Survey of aspects and evaluation of impacts using Cleaner

Production opportunities as a signicance lter.

4.3.1- Objectives and Goals

4.3.2- Environmental Management Programs

Objectives and goals made viable through projects with a focus on

Cleaner Production.

4.4.1-Structure and responsibility Resources for the implementation of such projects

4.4.2-Training, raising awareness and competence.Raising awareness; training for the implementation of Cleaner

Production projects (methodology, concepts and technology).

4.4.6- Operational Control

Activities identied as Cleaner Production opportunities must

be planned and programmed in order to provide support for all

activities in the projects implemented.

4.5.1-Monitoring and measurement

Creation of indicators to monitor results and parameters related

to the projects, and as a consequence, of objectives and goals to

be reached.

4.5.4-EMS internal auditingIndependent verication of the rhythm of Cleaner Production

provisions.

4.6- Critical analysis by the administration

Semiannual/annual balance sheets with inclusion of results and

proposals for improvements, with Cleaner Production projects as

an important input.

Souce: base on Pestelo an Azeveo (2000).

Table 2 emphasizes the equiements of the envion-mental system based on ISO 14001:2004, which ma be consiee points of insetion fo concepts of theCleaner Production model.

ANALYSIS AND DISCUSSION OF RESULTS

In tems of envionmental impacts, waste is the geat-est poblem an the essence of Cleane Pouctionis the optimization in the use of natual esoucesan the euction o elimination of waste. Thus, theaim of this item is to analyze the Waste ManagementSystem and the way natural resources are used inthe compan stuie.

Accoing to the inteviews caie out, geneation

an estination of waste ae not the main peoccu-pation egaing the maintenance of the Envion-mental Management Sstem in the compan. It waspossible to veif that 85% of the inteviewees be-lieve that the Environmental Management System base on ISO 14001 is not sucient fo a goo pe-fomance in envionmental conuct. Onl 10% of

the interviewees demonstrated that they knew aboutan coul ientif concepts of the Cleane Pouc-tion Pogam evelope b UNEP (1998). The mainconcepts ientie ae elate to actions aiming topevent an minimize waste at souce.

Figue 3 pesents the items an the impotance at-tibute to them b inteviewees, epesenting themain concens egaing the EMS implemente.


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Figure 3: Concerns regarding the EMS

63

58

53

47

32

21

42

32

47

42

16

0

16

5

26

0 10 20 30 40 50 60 70 80 90 100

Complice with legal environmental requirements

Audits

Environmental Stock Liabilities

Waste destination

Waste generation

[%]

Very important Quite important Less important Not important

'

Source: based on the results of the interviews

Accoing to Figue 3, 63% of the inteviewees ene “Compliance with legal envionmental equiements” as“ve impotant” fo the EMS implemente. The item “Auiting” was consiee “ve impotant” b 58% of theinteviewees. “Envionmental liabilities”, “ Waste destination” an

“Waste Geneation” wee egae as “ve impotant” b 53%, 47% an 32% of the inteviewees espectivel.

The ata below efe to the analsis of ocuments an ecos in achives petaining to the EMS of the com-pan an to diect an Paticipant Obsevation.

4.1 WASTE GENERATING PROCESSES AND DESTINATION

Pouction pocess analses wee caie out b means of iect obsevation, examination of the EMS ocu-ments an inteviews that esulte in the pouction of Table 3, which etails the stages in the pouctionpocess with the waste geneate in each stage an its estination.

Table 3: Stages in the production process, waste and destination.

Item WASTE GENERATED DESTINATION

1Sanitary waste; rubble; asbestos roof tiles; litter from sweeping and cleaning; Efuent

Treatment Plant sludgeLandll site

3 Waste from clinic; material contaminated with paint, oil and solvent Incineration

4 Wood Burned in furnace

5

Paint dregs; oxycutting dregs; cooking oil; used batteries; industrial cloth contaminated

with oils and grease; burned light bulbs; anti-friction oil; water contaminated with grease

remover; solvent; oil emulsion; tires and rubber

External recycling

6 Oxycutting scraps; metal scraps; paper, plastic and cardboard; metal splinters External recycling (sale)

7 Water contaminated with paint, solvent and oil Internal Recuperation

8 Cesspool sludge External treatment

9 Coal and quartz; hydrocarbon; coal contaminated with hydrocarbon Not dened

Souce: base on the compan’s EMS ocuments (2006)


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The classication of the estination of each tpe of waste, pesente in Table 3, was base on the citeia e-ne b LaGega (1994), UNEP (1998) an (CNTL/SENAISENAI) (2003).

With the analsis of ocuments, Instuctions, Intenal Communications, Euent Teatment Plant OpeationContol chats an Sevice Oes available, it was possible to veif that the compan geneates 34 tpesof waste; 27 ae monitoe though Waste destination Chats an 5 of those tpes ae consiee Envion -mental Inicatos an ae pesente in the oganization’s Envionmental Management Plan. The ae: woo,mateial fo incineation, lanll, paint egs, pape/plastic an caboa.

The analsis of the costs of the most signicant waste geneate le to the elaboation of Figue 4, which pes-ents the most impotant items of waste, classie accoing to impotance in tems of costs.

Figure 4: Most signicant waste and destination costs

Most significant waste [US$]

0

10.000

20.000

30.000

40.000

Wood ETP Sludge Incineratedmaterial

Paint dregs Sanitary

U S $

Souce: Base on the compan’s EMS ocuments (2006)

In Figue 4, it ma be obseve that woo is esponsible fo the highest annual cost incue b the compan with

waste estination, even though the estination fo buning in the funaces accounts fo onl 3% of the total, con -sieing all tpes of estination.

The annual cost incue fo the estination of the Euent Teatment Plant sluge is the secon highest. It shoul be note that the wate teatment pocess accounts fo 18% of all tpes of waste geneate in the compan an isesponsible fo the geneation of appoximatel 15,000 kg of sluge per annum.

destination of waste fo incineation costs about US$ 22,000 pe ea, although onl 6% of all tpes of waste aeispose of though incineation.

The costs incue fo the estination of paint egs oiginating fom the timestal cleaning of paint boothsplus sanita waste come up to appoximatel US$ 17, 000 pe ea. Paint egs ae the most signicant wastesent out fo extenal eccling – appoximatel 34,000 kg/ p.a. at a eal cost of US$ 11,000.

4.2 STRATEGIES FOR REDUCTION, WASTE CONTROL AND USE OF NATURAL RESOURCES

Stategies fo each tpe of waste geneate ma be ientie an analze, with gue 5 as a basis. It pesentsthe techniques fo waste contol that ae being aopte b the compan at pesent, base on the EnvionmentalManagement Sstem implemente.


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Figure 5: Techniques for waste control

Techniques for waste control

External

recycling; 31%

External

recycling (sale);

12%

To get back;

18%

Burning in

furnace; 3%

Landfill; 15%

Incineration; 6%

External

treatment; 3%

No defined; 12%


It shoul be stesse that, accoing to the intevie-wees, waste geneation is not the main concen asregards the Environmental Management System im-plemente. Compliance with legal equiements anexternal Environmental Auditing are mentioned bythe interviewees as the main concern regarding theEnvironmental Management System maintenance.

The aim of this item is to analze the pactices aoptefo waste euction, consieing the EMS implemente,an which concepts fom the Cleane Pouction Po-gam ma be use with a view to impoving the envi-

onmental conuct of the compan. This analsis was based on the results obtained in the case study and inthe evision of the liteatue, incluing the Envionmen-tal Protection Technology Evolution chart suggested by

LaGega (1994); an the Cleane Pouction Flux po-pose b UNEP (1998) e CNTL/SENAI (2003).

The evaluation of the compan’s envionmental con-uct, base onl on the Cleane Pouction Flow chat(Figue 1), aopte b UNEP an CNTL/SENAI, manot inicate impotant aspects that ae veie whenLaGega’s iagam of technolog evolution an envi-onmental poceues is use. This iagam consiesthe End of Pipe technologies as the stating point fo theevolution of stategies aopte to euce pollution.

Table 4 lists the citeia fo pioit level classica-tion of waste eucing altenatives, as popose bUNEP e CNTL/SENAI (2003), an the evolution ofwaste reduction strategies suggested by LaGrega.

Table 4: Evolution of pollution reduction strategies based on Cleaner Production

CLEANER PRODUCTION TRANSITION END OF PIPE

Level 1 Level 2 Level 3 RecuperationTreatment and

disposal

Reduction at sourceInternal

recycling

External

recycling

Biogenic

cycle

Modication

of waste to be

used as a sub-

product or for

reutilization of

heat generating

power

Treatment

of waste for

destination.

Waste Stock

Exchange

Incineration.

Final disposal

(landll sites)

Modication

Product and /or process

Waste as

raw material

for other

processes

Recuperation

of more

valuable raw

materials,

with

reintegration

into the

economic

cycle

Good

Operational

Practices

(GOPs)

Raw

material

substitution

Technological

changes

Reuse of

waste, without

alteration of

characteristics,

generated in

the company

Souce: base on LaGega (1994).


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Table 4 poposes that the analsis of stategies a-opte fo pollution euction shoul be one con-sidering End of Pipe technologies, the phase of tan-sition in environmental conduct between End of Pipean Cleane Pouction an pioit levels in theCleane Pouction pogam.

4.2.1 End of Pipe Technology

Accoing to de acooKipestok et al (2000), wasteisposal in lanll sites of an kin chaacteizesthe aoption of End of Pipe strategies. As observedin Table 3 an Figue 5, waste estine to lanllsites epesents 15% of all waste geneate, al-though 100% of that waste oiginates in seconaactivities in the compan stuie. Kitchen an toi-let waste, as well as waste fom efubishing anemoeling, ae estine to Class II lanll sites;

sluge esulting fom euent teatment is estineto Class I lanll sites.

According to LaGrega et al (1994) an to Table 4,waste incineration is also considered an End of Pipestateg, an coespons to themal oxiation un-e high tempeatues. This pocess is aopte toreduce volume and weight.

Waste estine to incineation epesents 6% of thewaste geneate in the compan, with 99.5% of itgeneate in the painting pocess an appoximatel0.5% esulting fom activities in the compan’s clinic.

In this specic case, “waste estine fo extenalteatment” is the sluge fom the cesspools ankitchen sewage inspection boxes, which is estineto SABESP (the local wate an sewage compan)fo appopiate teatment an epesents 3% of allwaste geneate b the compan. As shown in Figue5 an table 3, 12% of the waste is awaiting enitionfo extenal teatment o nal isposal, accoing tolegislation. At pesent, this tpe of waste is stoe inmetal containers in the area set aside for waste.

Although the ieent tpes of waste mentionein the pevious paagaph ae classie as “not e-ne” in Figue 5, the petain to End of Pipe tech-nolog, accoing to Table 4, since that waste is es-tine to classie lanll sites o iecte fo exte-nal teatment, as it has chaacteistics that peventits use in the intenal eccling pocess at pesent.Consieing the couse of action aopte fo wasteestination, it can be notice that End of Pipe technol-og is emploe fo 36% of the waste geneate inthe compan.

4.2.2 Transition between End of Pipe technologyand Cleaner Production

Accoing to Kipestok et al (2000) an LaGegaet al (1994), the caloic powe of waste use as fuelan the moication of liqui euent to be useas a sub-pouct ae classie in the aea of tansi-

tion between End of Pipe technologies and CleanerProduction.

The analsis of Table 243 an Figue 35 shows thatTransition between End of Pipe and Cleaner Produc-tion is the technique aopte fo waste woo anfo wate contaminate with oil, paint an oxcut-ting dregs.

To Chistie, rolfe an Legan (1995), ecupeationof the eneg in waste, though buning, an eu-ent teatment fo use as sub-pouct ae avisable

techniques, but onl fo waste that is impossible toavoi ae impovements in the pocess.

Woo buning in funaces (3%) an intenal ecupea-tion of contaminate wate (18%) pesente in Figue5 ae classie as Tansition Techniques between Endof Pipe technologies and Cleaner Production.

The analysis of waste control documents showedthat thee was a signicant incease in the genea-tion of woo as waste in the compaison betweeneas 2005 an 2006 ( until Jul/06). It shoul bementione that the incease was ue to moica-tions in the fokli tuck manufactue, which e-mane the substitution of supplies, an the usewoo cates as the main fom of packaging pats.No action that coul eectivel lea to euction ofwood as waste was observed.

Wate contaminate with oil, oiginating both fomwashing facto oos an equipment, an fomcontention an compesse ai geneation boxes isteate in the Euent Teatment Plant, b means ofa chemical pocess an late euse as a sub-po-uct in the paint lteing sstem, fo washing fokli

tucks an fo efigeation in oxgaph cuing.

Accoing to Fink (1995), the implementation of awater reuse system aims at reducing environmentalimpacts an pomotes bee envionmental pac-tices. Wate euse in the pouction pocess ma be a viable altenative, which will, in conjunctionwith technical, economic an envionmental evalu-ation of the pouction pocess an of the pouct,esult in continuous impovement an a euctionof costs.


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4.3.3 External Recycling and Reintegration to the biogenic cycle (Level 3)

Accoing to Table 254, waste contol techniques classie at Level 3 coespon to extenal eccling tech-niques o biogenic ccle. In Figue 5, “extenal eccling 31%” efes to waste that is ispose of though pa-ment of the geneating compan; “extenal eccling (sale) 12%” efes to waste that is sol to companies thatuse it as aw mateial. Theefoe, the oveall sum of waste estine to extenal eccling is 43%.

As seen in Table 3, waste estine fo extenal eccling consists of, among othe things, paint egs; oxcut-ting egs; cooking oil; use baeies; inustial cloth contaminate with oils an gease; light bulbs; anti-fiction lubicant; wate with gease emove; oil emulsion an ubbe.

“Extenal eccling (sale)” efes to metallic waste geneate in the pouction pocess o in maintenance ac-tions an is pesente in Table 5.

Table 5: Waste classied for external recycling

WASTEQtty. (kg) Sale Value (R$)

2004 2005 2006 2004 2005 2006

Oxycutting scraps 285,290 503,350 566,460 71,323 125,838 142,027

Metal scraps in general 153,990 241,890 211,530 26,178 41,121 36,172

Metal splinters 144,040 227,140 80,612 11,523 18,171 6,770

Paper, plastic and cardboard 61,124 87,220 82,676 3,056 4,361 4,134

Total 644,444 1,059,600 940,278 112,080 189,491 189.103


It shoul be note that in the columns make“Quantit” an “Sale value” fo the ea 2006, thevalue coespons to eleven months of activities, i.e. Janua to Novembe 2006. The analsis of Table 5indicates that there was a reduction in the genera-tion of splintes fom the manufactue of metal castpieces, even taking into consieation the fact thatthe index refers to eleven months of activities.

Each tpe of metallic waste estine to extenal e-ccling (sale) has ieent maket values epen-ing on their condition. According to the analysisof the chats the compan eceive appoximatelUS$100,000.00 fo the sale of metallic waste. It shoul be stressed that the Cleaner Production Programgives pioit to actions that aim fo euction ofwaste at the geneating souce, with eccling tech-niques being classie as a Level 3 stateg.

Accoing to Babiei (2004), Level 3, though liste asone of the classication citeia fo Cleane Pouc-tion altenatives, shoul not be given pioit oveLevels 1 an 2 in the Cleane Pouction Pogam.

4.2.4 Internal Recycling (Level 2)

Intenal reccling is ene as euse of wastegeneate in the compan itself in the conitionin which it is geneate , i.e. without teatment o

moication of phsical an chemical chaacteis-tics. In this case stu, actions classie as Level2 altenatives fo waste euction wee not note,accoing to Table 4.

4.2.5 Reduction at source (Level 1)

Accoing to Fiemann (1997), at Level 1 pio-ity should be given to actions that aim at reducinggeneation of waste at the geneating souce, withcitical evaluation of mateials use in the poucts.Though the analsis of EMS ocuments, besiesobservation and interviews carried out with thoseesponsible fo the management of the envionmen-tal sstem, it was possible to veif that onl actionselate to Goo Opeational Pactices ae foun at

Level 1 of the classication citeia (pioit level al-tenatives to minimize waste).

The installation of tanspaent oof tiles in StockContol aeas an changing ooms, maximizing theuse of natual light, an the moe fequent main-tenance of eighteen welding machines in order toimpove the use of electicit ae Examples of GooOpeational Pactices implemente in the companae examples of Goo Opeational Pactices imple-mente in the compan.


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As to changes in the pouct, it coul be noticethat thee was no alteation in the pouct aimingat minimizing envionmental impacts. Similal, nochanges were observed in technology or the use ofraw material.

4.2.6 Use of Natural Resources

Bee use of natual esouces is emphasize atLevel 1 of the Cleane Pouction Pogam. A e-duction in the generation of waste and emissions atthe souce ma occu though moications in thepouction pocess b means of Goo OpeationalPactices. These ae the most aequate actions, sincethe optimize the use of natual esouces.

In this case stu, the natual esouces stuie weewate an electicit, which ae egae b the com-pan as envionmental gauges an an integal patof the Environmental Management Program.

Table 6 is base on the Envionmental ManagementPlan – EMP. It pesents the pe-capita consumptionof drinking water.

Table 6: Water consumption

Year Consumption (m3/person)

2004 3.11

2005 2.83

2006 2.33


Though the index is calculated based on the numberof people, it was obseve that this esouce is usein the inustial aea as a complement to teate wa-te, besies being use in the inustial kitchen, toi-lets, lavatoies an showes. The wate suppl ss-tem onl measues consumption of public supplwate; theefoe, it was not possible to obtain patialconsumption ecos to veif how much inkingwate is consume in the pouction aea.

As obseve in Table 6: Wate Consumption, theewas a euction of appoximatel 10% in mean wa-te consumption between 2004 an 2005. Between2005 an 2006 it ecease b 21.45%. These pe-centages of reduction may be credited to actionsof incease use of teate wate in the pouctionpocess, fo example, to wash fokli tucks an aswate cutain in the painting pocess. Awaenessaising campaigns fo euction an ational useof drinking water were noted in the Environmental

Management Plan and during observation in thefacto’s pemises.

It was notice that the liqui euent teatment po-cess, classie as Tansition Technolog, is iectleecte in inking wate consumption in thecompan. Accoing to inking wate consump-tion contol ecos, the use of teate wate in thepouction pocess instea of inking wate esultsin a euction of appoximatel 54 cubic metes ofwate pe month, since mean consumption of thisesouce is 530 cubic metes.

In Table 7: Electicit Consumption, electicit con-sumption pe machine pouce is pesente.

Table 7: Electricity consumption

Year Consumption (MWh/machine produced)

2004 -x-x-

2005 0.79

2006 1.12


rates fo the ea 2004 ae not pesente, becauseuntil that year the indicator was obtained consid-eing the atio of electicit consumption to housof wok. reseach into electicit consumptionchats an pouction inices (Kw/hou of wok)veie that the inicato Kilowa/hou pe hous

of wok i not epesent the eal situation of en-eg use in the compan. Fom 2005 onwas, anew inicato was aopte—Megawa pe ma-chine pouce—(MWh/mach.pouce) an,according to the Environmental ManagementPlan, the lowe the inex, the bee the use in thepouction pocess.

Ae analzing the stategies fo euction of wastean natual esouces use, the next item pesentsthe contributions of the Cleaner Production Programto an Envionmental Management Sstem cetie

to ISO 14001.

4.3 CLEANER PRODUCTION CONTRIBUTIONSTO ISO 14001

Actions related to the Cleaner Production strategiespesente in the liteatue ae iecte towas thecauses and the understanding of waste generation.In the End of Pipe technolog appoach, the stactions aopte ae usuall aequate isposal owaste treatment.


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Table 8 snthesizes actions aopte b the compan to euce pollution, listing the kin of technique usean the numbe of actions implemente.

Table 8: Pollution reduction techniques and number of actions implemented

LEVELS AND TYPES OF TECHNIQUES TO REDUCE POLLUTIONNUMBER OF ACTIONS

IMPLEMENTED

LEVEL 1 (CP)

Product or process modication 0

Raw material substitution 0

Modication of technology 0

Good Operational Practices - GOPs 2

LEVEL 2 (CP) Internal Recycling 0

LEVEL 3 (CP) External Recycling and biogenic cycles 16

TRANSITION

(Fim de Tubo / P+L) Transition stage ( End of Pipe + CP) 7

END OF PIPE Waste treatment, incineration, landll 11

Total 36


As obseve in Table 8, End of Pipe actions (wasteteatment an isposal technologies) ae evientamong the moalities aopte to euce pollution,

with a total of eleven actions pesente in Table 3:Stages in the pocess, waste an estination.

It is impotant to egiste that the EnvionmentalManagement Sstem cetie to ISO 14001 oes notestablish conditions to minimize the use of End ofPipe techniques. As to Cleane Pouction metho-olog, it oes not ecommen the aoption of thesetechniques, but it oes not isca them eithe.Accoing to Chistensen (2002), a geate concenabout waste geneating pocesses is evient in com-panies making use of clean technologies.

Seven actions classie at the level of tansition be-tween End of Pipe techniques an Cleane Pouctionae pesente in Table 3. Wheneve possible, Level

1 (euction at souce), followe b Level 2 actions(intenal eccling) shoul take pioit; in the com-pan stuie, pioit is given to Level 3 in the Flow

chat (extenal eccling an biogenic ccles). Thecompan has been esoting to extenal eccling asthe main technique fo isposal of waste, since six-teen actions using this appoach wee ientie.

As to Goo Opeational Pactices, onl two actionswee ientie. Accoing to the liteatue efe-ing to Cleane Pouction appoaches, Goo Op-eational Pactices usuall coespon to low costsan eas applicabilit.

The pecentage of use of each tpe of stateg fo waste

euctions is epesente in Figue 6, emonstatingthat 31% of the actions aopte to euce an contolwaste refer to End of Pipe techniques, i.e. actions aimingat waste teatment, incineation an nal isposal.


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Figure 6: Use of strategies for waste reduction and prevention

Use strategies for waste reduction and prevention

Transition

19%

End-of-pipe

31%

Level 3

44%

Level 1

6%Level 2

0%

Source: based on the company’s EMS documents (2006)

The actions classie between End of Pipe and Level

3 epesent 19% of the total an, accoing to Table 3,in this case stu ae name Tansition Techniques,which chaacteize the pocesses of waste moi-cation fo use as sub pouct o fo euse of caloicpowe. Level 3 accounts fo 44% of waste euctionactions, i.e. the ae basicall extenal eccling ac-tions in which waste generated is used as raw mate-ial in othe companies.

As seen in Figue 6, no actions wee note fo Lev-el 2. At Level 1, onl actions that ae not elate towaste pevention o minimization wee foun; the

are actions that aim at directly or indirectly reducingthe consumption of natual esouces, such as watean electicit, an account fo 6% of pollution pe-vention actions.

The results of this study demonstrate that the com-pan in question, espite having an EnvionmentalManagement Sstem cetie to ISO 14001, still en-gages in non-satisfacto envionmental conuct, asegas waste, albeit with a tenenc fo evolution.Figue 4 shows that 94% of the actions aiming at pol-lution pevention an euction ae classie be-

tween End of Pipe Techniques an Level 3 (Extenalreccling). These techniques ae compatible withthe envionmental stateg, which is peominantleactive, since the emphasis at pesent is on compl-ing with the legislation in force and on conformitywith ISO 14001. To Cobe (2001), ISO 14001 oesmoe, in envionmental tems, fo itie facilitiesthan for cleaner ones.

Klassen (1999), suggests that senio management toassist plant manges to become moe poactive anto impove envionmental pefomance.

5. CONCLUSION

Cleane Pouction concepts ecommen waste e-uction o suppession. It ma be conclue that anEnvionmental Management Sstem base on ISO14001 an complemente with Cleane Pouctionwiens the context fo envionmental pefomanceimpovement.

ISO 14001 cetication has been value as a paametefo companies’ envionmental qualication, an conse-quentl, as a stategic avantage in the ght fo maketpositions, consieing the value aibute to the envi-onment b some segments of societ. Thus, cetica-

tion is iectl associate to envionmental qualit.

It can be veie that ISO 140001 cetication con-tibutes to impoving envionmental managementin companies. That Sstem complies with envion-mental legislation an equies a commitment ofthe cetie compan to a continuous seach fo im-povement in envionmental actions.

Howeve, the EMS cetie to ISO 14001 can gene-ate a climate of false tanquilit, in which the sstem behaves satisfactoil fom a nomative point of view,

but the envionmental pefomance itself ma not besatisfacto, since this moel oes not epesent en-vironmental excellence but is rather a managementfame in the seach fo continuous impovement.

The scope of the insetion of a Cleane PouctionPogam into an EMS alea implemente e-pens on the economic, technological an manage-ial capacit available. Cleane Pouction emansorientation towards innovation and a continuousimpovement pocess, with an accumulation of ex-peience an esouces save with the st inte-


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ventions, poviing impulse fo new actions. It isobvious that a zeo emission taget is not aainablethoughout the pouction chain, since tansfoma-tion without loss is a phsical impossibilit, but it isapplicable to specic questions, such as the elimina-tion of toxic waste.

The envionmental stateg of peventing pollu-tion pesupposes the aoption of Cleane Pouc-tion concepts, which epesent the base of HighPefomance Envionmental Management. In thisstateg, the best economic altenative is the elimi-nation, athe than the management of envion-mental impacts, i.e. the focus is the opposite of Endof Pipe Technologies.

This case study showed that the Cleaner ProductionPogam ma oe contibutions to an Envionmen-tal Management Sstem cetie to ISO 14001, since

the Cleane Pouction appoach favos solutionsaiming at waste euction an pevention, suggest-ing that companies act at the geneating souce, seek-ing altenatives fo the evelopment of an eco-e-cient pocess, esulting in non-geneation of waste,in euction, in intenal o extenal eccling.

The integration of the Cleaner Production Programwith the Environmental Management System certi-e to ISO 14001 guaantees bee knowlege ofthe inustial pocess b means of constant moni-toing fo the maintenance an evelopment of an

eco-ecient pouction sstem, with the geneationof envionmental an pocess inicatos. This moni-toing allows the compan to ientif applie e-seach, technological infomation an taining po-gram needs. The Cleaner Production Program can be integate with Qualit Sstems, EnvionmentalManagement an Occupational Safet an Health,esulting in complete unestaning of the compa-n’s management sstem.

The Cleaner Production Program brings environ-mental an economic benets that esult in global

ecienc in the pouction pocess, though elimi-nation of avoiable losses, minimization o elimina-tion of aw mateials an othe supplies that have anegative impact on the envionment, a euction ofwaste an emissions, a ecease in waste manage-ment costs, minimization of envionmental liabili-ties, impovement in health an safet at wok.

Accoing to this stu, the moel of managementpopose b ISO 14001 favos the pactice of man-aging waste and administering the environmental

impacts of the activities of the compan. In temsof envionmental pefomance, bee esults ma be obtained when the Cleaner Production Programconcepts ae aggegate as a complementa instu-ment to the Environmental Management System cer-tie to ISO 14001, esulting in a sustainable EMS,

consieing that the implementation of the CleanePouction Pogam emphasizes waste peventionat the source.

As observed in the literature and through analysesan obsevation of the compan’s ocuments, thecontinuous impovement emane b ISO 14001is no guaantee of signicant impovement in en-vionmental pefomance, since the compan maajust to the nom with an inecient managementmoel. The stanaization of poceues eman-e b nomalization ma make the compan aopt

coect taitional poceues, but with poo envi-onmental pefomance; theefoe, the Cleane Po-uction appoach is a necessa complement to theEnvironmental Management System.

Fo futue stuies, it is ecommene that easonsfor use of End of Pipe technologies be veie, to seeif this is ue to a behavio of esistance to change,which pevents the aoption of a postue base onPollution Pevention, o whethe the cause lies in theignoance of the existence of altenative moels, oin estictions on nancial investment.

BIBLIOGRAPHY

BArBIErI, Calos J. Gestão Ambiental Empesaial – Conceitos,Moelos e Instumentos. São Paulo: Saaiva, 2004.

CNTL - SENAI rS. Manual e Implementação e pogamas ePoução Mais Limpa. Poto Alege: Cento Nacional e Tec-nologias Limpas Senai-rS/UNIdO/UNEP, 2003.

CHrISTENSEN, Pe Coping with the Envionment – danishcompanies an thei expeiences with ISO 14001/EMAS. The Jounal of Tansisciplina Envionmental Stuies, vol.1, n.1, 2002, ISSN 1600-2297. disponível em Acesso em 25 e maio e 2006.

CHrISTIE, I.; rOLFE, H.; LEGrANd, r. Cleane Pouction inInust, Lones, Polic Stuies Institute, 1995.

COBErTT, C. J., rUSSO M. V. The impact of ISO 14001. ISOManagement Systems.

EISENHArdT, K.. M.; GrAEBNEr, M. E. Theo builing fomcases: Oppotunities an challenges. Acaem of Manage-ment Jounal 2007, vol. 50, n. 1, 25-32.

FINK, ronal G. reccling waste wate. Pit & Qua, jul-95,vol. 88, p.23, 3p. ISSN-0032-0293.


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FrIEdMANN, C. Aspectos tecnológicos e la gestion e esíu-os. In FUENTE, H. d. e la (og). Gestion ambientalmenteaecuaa e esíuos sólios. CEPAL/GTZ. Santiago eChile, 1997.

FUrTAdO, João S. e FUrTAdO, M. C. Poução Limpa, inContao, J. C. (coo.) Gestão e Opeações. Funação Van -zolini & Eitoa Ega Bluche Lta., São Paulo, 1998, p.

317-329.

KIPErSTOK, A. Ecologia Inustial e pevenção a poluição:Uma contibuição ao ebate egional. TecBahia, Camaçai,v.15, n.2, p.47-55, maio/ago 2000.

KLASSEN, r. d., WHyBArK, d. C. Envionmental managementin opeations: The selection of envionmental technologies.decision Sciences, Summe, 1999, 601-631.

KLASSEN, r. d., MCLAUGHLIN, C.P. TQM an envionmen-tal excellence in manufactuing. Inustial Management andata Sstems, 1993, 14-22.

BIOGRAPHY

Fernando M. Cervelini , eane his Maste’s egee in Aministation with emphasis on Pouction Contolat Nove e Julho Univesit an Bachelo’s degee in Electic Engineeing at Mogi as Cuzes Univesit.Nowaas, he is a pofesso of Cleane Pouction an Sustainabilit development at Estácio UniraialUnivesit. He also has hel seveal positions at multinationals companies in Bazil acting since 1987 in aeas

as inustial maintenance, envionmental an manufactuing.

Maria Tereza Saraiva de Souza is Pofesso at the Nove e Julho Univesit. In the doctoate an Mastes´s de-gee Pogamme, she teaches classes about Envionmental Management an also avises stuents in thei oc-toate thesis an Maste´s egee issetation eveloping eseach in the el of Envionmental Management.

She has publications in the main Business Aministation Congesses, with emphasis on sustainabilit, socialesponsibilit, evese logistics, geen-suppl chain management an Cleane Pouction. She has expeiencein acaemic aministation, such as the epatment hea uing the peioo 1994-2006 an othes executivepositions in bazilian univesities.

She eane a doctoate an Maste’s egee in Business Aministation fom EAESP/FGV.

LAGrEGA, Md ET AL. The Envionment esouce ManagementGoup: hazaous waste management, 1st e. Singapoe. Mcgaw-Hill, 1994, 1146p.

PrESTrELO, r.C; AZEVEdO, P. r. ISO 14000 & PouçãoMais Limpa: solução paa um Sistema e Gestão Ambientalmais efetivo ou abangente. 2000. 80f. Monogaa (Espe-cialização e Geenciamento e Tecnologia Ambientais na

Inustia) Escola Politécnica, Univesiae Feeal a Bahia,Salvador.

NICOLAJ, SIGGELKOW. Pesuasion with case stuies. Aca-em of Management Lounal 2007, Vol. 50, n. 1, 20-24.

UNEP – declaação Intenacional sobe Poução Mais Limpa.1998. disponível e Acesso em: 02 junho 2006.

yIN, r. K. Estuo e Caso – Planejamento e Métoo. PotoAlege: Bookman, 2001.

Documents

A Contribution of the Cleaner Production Program To