Guidebook on Waste Minimisation for IndustriesTABLE OF CONTENTS Acknowledgements CHAPTER 1: INTRODUCTION Overview of the Solid Waste Situation in Singapore NEA’s Strategies on Waste Minimisation Why Develop this Guidebook? CHAPTER 2: BENEFITS OF WASTE MINIMISATION What is Waste Minimisation? Benefits to Companies Benefits to Singapore CHAPTER 3: EIGHT STEPS TO A WASTE MINIMISATION PLAN Step 1 – Get Management’s Commitment Step 2 – Select a Waste Minimisation Working Team Step 3 – Conduct a Waste Audit Step 4 – Determine the True Costs of Waste Step 5 – Develop Waste Reduction Options Step 6 – Assess the Scope of Savings & Rank Options Step 7 – Develop a Waste Minimisation Plan Step 8 – Implement and Improve the Plan CHAPTER 4: CASE STUDIES Baxter Healthcare Pte Ltd Chevron Oronite Pte Ltd IBM Singapore Pte Ltd Kyoei Engineering Singapore Pte Ltd Sony Display Device (Singapore) Pte Ltd Tetra Pak Jurong Pte Ltd REFERENCES ACKNOWLEDGEMENTS The National Environment Agency (NEA) would like to thank the following organisations for their participation in the Working Group to produce this Guidebook and for their invaluable contributions and support: i) JTC Corporation, ii) Singapore Manufacturers’ Federation, iii) IBM Singapore Pte Ltd, iv) Sony Electronics (Singapore) Pte Ltd and v) Waste Management and Recycling Association of Singapore The NEA would also like to thank the following persons and their companies for their contributions of the best practices in waste minimisation & recycling to the Guidebook and for their invaluable advice and suggestions: i) Ms Shirley Pang [Baxter Healthcare Pte Ltd] ii) Mr Ting Eeng Hoe [Baxter Healthcare Pte Ltd] iii) Mr Alan Chong [Chevron Oronite Pte Ltd] iv) Mr Lim Tew Team [Kyoei Engineering Singapore Pte Ltd] v) Mr Windsor Chan Jr [IBM Singapore Pte Ltd] vi) Mr Chan Pheng Hwa [Sony Display Device (Singapore) Pte Ltd] vii) Mr Ong Lye Huat [Tetra Pak Jurong Pte Ltd] Our special thanks also to Dr Tan Kee Wee, (Director, Research & Corporate Communications of Singapore Manufacturers’ Federation) for editing the Guidebook. We would like to thank all who had provided feedback and suggestions. 1 about 90% of the waste is disposed of by incineration thus reducing the landfill space taken up by waste very significantly. Singapore would need to build a new incineration plant every 5-7 years and a new landfill the size of Semakau Landfill every 25-30 years. about 60% of the waste generated by industries was recycled. building and operating new disposal facilities is very costly and could only lead to a higher refuse disposal fee. With the rate of growth in solid waste. reduce the demand for land to build the facilities. The third is to reduce waste going directly to landfills. and maximise recycling. the solid waste disposed of in Singapore has increased 6-fold. a statutory board under ENV) has adopted three strategies. The incineration plants have been designed to incinerate waste safely and fitted with air pollution control equipment. Since 1979. the Singapore Green Plan (SGP) 2012 sets the following key targets: 2 . Non-domestic waste increased even more by about 8-fold mainly from the high growth in the manufacturing and services sectors. The sustainable waste management solution is to minimise waste. and avoid unnecessary increase in the refuse disposal fee. the Ministry of the Environment (ENV) started to promote waste reduction and recycling in the 1980s and 1990s by adopting a policy of waste incineration to reduce waste volume and encouraging recycling. the last landfill on the main island of Singapore was filled up by 1999 and a new offshore landfill at Pulau Semakau was developed for non-incinerable waste. To achieve a long-term goal of sustainable waste management. Domestic waste increased about 3-fold. Such an approach would help to defer the construction of new disposal facilities. Strategies on Waste Minimisation It is not sustainable to go on building more waste disposal facilities to meet increasing amounts of waste. the National Environment Agency (NEA. One is to reduce waste going to incineration plants. the government has spent billions of dollars to build four incineration plants and sanitary landfills. The overall waste recycling rate for all waste was 45% in 2002. To step up the efforts. They effectively reduce the volume of waste for final disposal in the landfill and also recover energy and scrap metals. By 2002. Moreover. Even then.Guidebook on Waste Minimisation for Industries CHAPTER 1: INTRODUCTION Overview of Solid Waste Situation in Singapore Over the past three decades. Industries have also responded well and by 2002. Recognising the need to reduce waste. The other is to reuse incineration ash. to one every 10-15 years. The aim of the Guidebook is to assist companies to reduce waste at source and to maximise recovery of recyclable waste for reuse or recycling. Why Develop this Guidebook ? A growing number of manufacturing companies in Singapore has been practising “waste minimisation” at various levels and realised savings and other benefits. However. and striving “towards zero landfill”. Waste Management and Recycling Association of Singapore (WMRAS). In its broadest sense. Currently. the fact that our disposal facilities still receive large amounts of waste materials from industries indicates that there is still room for improvement. This would in turn lead to further improvement in productivity and profitability. • reduce the need for new incineration plants. plan and implement waste recycling programmes to meet the targets of the SGP 2012. reuse and recycling) that reduce the amount of waste entering the environment. The NEA has been working closely with various partners in the people. BENEFITS OF WASTE MINIMISATION What is Waste Minimisation? There are many ways to define waste minimisation. but not limited to: 3 . and implement a waste minimisation plan. JTC Corporation (JTC). Singapore Manufacturers’ Federation (SMa). from the current one every 57 years. This Guidebook is a joint effort of NEA.• increase the overall waste recycling rate to 60% by 2012. Studies show that there is scope to reduce waste at source and to recover more recyclables from the industrial sector for reuse and recycling. This Guidebook will provide companies with practical information on how to approach. waste minimisation includes all practices (including waste prevention. waste minimisation in industry means practices. private and public sectors to educate. More specifically. • extend the lifespan of Semakau Landfill to 50 years. and industries. and reduce waste. It also provides case studies of several companies that have achieved cost savings and waste reduction. including. plan. non-domestic waste from industries and commercial premises accounts for about 50% of the waste disposed at our waste disposal facilities. This can be done through improved resource and process efficiency. and cutting down of waste handling and disposal costs. etc. reduction of waste. Many companies’ experiences have demonstrated this. • Operational & maintenance procedure changes. • Equipment replacement or modifications. end-of-life take-back schemes. and gain a winning edge in the market place as preferred suppliers. consumables. A representation of a resource throughput is shown below. or waste which costs money to treat or dispose of. enhance their reputation by going green. competitive advantages to a company in two main ways: It can provide Improved Resource Efficiency & Cost Savings All the resources (such as raw materials. Several examples are given in Chapter 4 of this Guidebook on Case Studies. • Material changes. Many businesses have enhanced their relationship with customers through initiatives such as reusable transit packaging. energy. • Inventory management changes. water. • Reuse/recycling of waste materials. companies that make efforts to achieve waste reduction can also improve their public image. manpower and time) that a company puts into their business process will result in either products which can generate revenue. Improved Public Image & Winning Edge Furthermore. Benefits to Companies Waste minimisation has positive outcomes to industries.• Product design modifications. 4 . Revenue raw materials & consumables energy & water manpower & time Products Business Process waste (gaseous / liquid / solid) waste energy waste manpower & time Cost Cost Practising waste minimisation in any area of a business process can help reduce business costs. A 10% reduction in waste disposal would result in savings of $2 million or more each year. One of the options . processing and disposing the waste in land-scarce Singapore are expensive and resource intensive. This led to an intensive waste audit at every stage of the manufacturing process. and move a step closer to sustainable waste management and towards zero landfill. The company found opportunities to reduce. this represents a $200 million value per year in expense. Just as important. reuse and recycle waste. In turn. this Guidebook would help you move along step by step in developing and implementing a waste minimisation plan for your facility. They then formed a waste minimisation working committee. The steps are as follows: Step 1: Get Management’s Commitment Step 2: Select a Waste Minimisation Working Team Step 3: Conduct a Waste Audit Step 4: Determine the True Costs of Waste Step 5: Develop Waste Reduction Options Step 6: Assess the Scope of Savings & Rank Options Step 7: Develop a Waste Minimisation Plan Step 8: Implement and Improve the Plan 5 .the reuse of packaging materials found strong support with their customers . At the current refuse disposal fee of $77 per tonne. expand the lifespan of the landfill. EIGHT STEPS TO A WASTE MINIMISATION PLAN Your company may already have a waste minimisation plan or programme in place. waste minimisation helps to conserve finite natural resources.6 million tonnes of solid waste in 2002. and realised savings of about $1 million a year. the reduction in waste would help reduce the demand for new waste disposal facilities and the associated expenditure. If your company is starting from scratch.An electronic company used to spend large amounts of money on one-way packaging materials to deliver their products to customers. and in-house reduction targets were set. Or you could make use of the resource information listed in References section to further improve your plan. Benefits to the Nation Singapore disposed of 2. If so. you may use this Guidebook as a point of reference and go to the sections most appropriate to your needs.resulted in large reduction in packaging waste. Collecting. which conveys waste minimisation plan objectives to employees.Step 1: Get Management’s Commitment To stay competitive. You need to collect data on the amount of waste generated by your company and the cost of disposing it and estimate the potential savings today and in the future. process and product design. • Announcing the formation of a waste minimisation team and give the team the authority and responsibility. plant operations. to present your idea and proposal so that senior management has a chance to study and consider your idea and proposal. companies need to continually find new ways to improve efficiency and cut costs. The policy statement. it is important to get a clear direction on appointment of the appropriate personnel to take charge of the project and the time frame for implementation. and is as important to management as quality. is to give a clear and strong signal of the senior management’s commitment to support waste minimisation efforts. and • Showing interest and participating in key activities on waste minimisation. Request your senior management to demonstrate its support and commitment as follows: • Circulating or make known to all staff a policy statement on waste minimisation. • Keeping staff informed of plan and the progress of the project • Giving recognition as appropriate to the staff involved. If you are an environmental engineer or manager (or from any other departments). • Reusing and recycling materials before disposing them as waste. may include these main points: • Reducing waste at source to eliminate waste is the main goal in research. yield. and believe that there are scope to reduce waste in your facility. 6 . take this first step to propose a waste minimisation plan to your senior management to draw up and implement a waste minimisation plan. If you are the decision-maker of the company and would like to achieve the same benefits that other companies have reaped. which is an essential prerequisite for success. and loss prevention. When the senior management has made their decision. then the first step. safety. You should also find the most effective channel. increase operational efficiencies. In keeping with this policy. [Your Company] promotes environmentally-sound measures to reduce. reuse. How a company first distribute the written policy to employees indicates its commitment. and maintain a safe and healthy workplace for our employees. [Your Company] is committed to excellence and leadership in protecting the environment. or amend the language to suit your facility. and land. we can achieve cost savings. Employees are urged to come forth with suggestions for further reducing waste in their own work areas. 2. a waste minimisation working team need to be formed to make things happen. and recycle waste. each individual is responsible for reducing waste. through excellence in waste reduction. You may use them as the reference. and for complying fully with all waste reduction programme goals established by the company. As both a responsible citizen and [Company] employee. This will help to send a positive signal to employees and get them involved and treat the matter seriously. A company needs to select a waste minimisation working team. and being an environmentally-responsible corporate citizen. cost reduction. and ask employees for their ideas. These could be product quality improvement. and in any other areas which they may have ideas. improve the quality of our products and services. Examples of Policy Statements 1. We suggest that you call a special meeting to explain and distribute copies of your company's policy. you may also want to list certain motivations for waste minimisation. We strive to minimize adverse impact on the air. Following are some examples of policy statements. our objective is to reduce waste and emissions. By successfully reducing waste at its source. and give the leader sufficient authority to lead the team. water. identify a competent team leader. Step 2: Select a Waste Minimisation Working Team Following the policy decision.In the policy statement. The team leader would best possess the following attributes: 7 . [Your Company]'s policy is to reduce all waste to the minimum levels that are economically and technically feasible. Posting it unexpectedly at work stations could send a negative message. display it prominently and distribute it widely. Once management signs and dates the policy statement. or packaging that they are supplying. Suppliers would have the technical knowledge about the raw materials. and from different sections / departments / divisions and levels such as : • Management • Engineering / design • Production • Maintenance • Purchasing • Accounting / Finance • Shipping / Receiving It may be useful for the team to involve the company’s suppliers in the planning process.). its production processes. For the same reason. Step 3: Conduct a Waste Audit Solid waste in a manufacturing facility is usually generated in three areas: • manufacturing (wastage of raw material and process waste). Preferably. it would be helpful to involve your company’s customers in the process. They may also have experience with their other customers on similar projects and can share information and success stories.• Familiar with the facility. and perception of the issues. etc. and its waste management operations • Familiar with quality control requirements • Good rapport with management and employees • Familiar with waste reduction principles and techniques • Familiar with new production and waste management technology The size of the team can vary depending on the complexity of the company’s operation. the members would be well represented in terms of experience. or equipment. • shipping and receiving (packaging waste). • office operations (paper and print cartridge waste. 8 . knowledge. and • how they are managed after being generated. but it helps to identify areas of wastage and problems. and discover opportunities to reduce them in the later stage of planning. • quantity of each waste stream.Understanding the waste generated in these areas is an essential step and can be done through conducting a waste audit. mixed with other types of waste): 9 . and • talking to the relevant employees. Create a checklist for all waste streams and use a waste assessment sheet for each waste stream identified from all activities / processes / operations. records of waste and rejects produced at generation points in daily operations. • walking through different operational processing areas. kg/unit of product): Potential for contamination (e. An example of a waste stream assessment sheet is as follows: Date: Process / Operation / Activity: Profile of waste: Type of Waste: Point of origin: Quantity/month: Physical & chemical properties: Rate of generation (i. • how they are generated.g. Doing this alone will not reduce waste. • surveying the waste in the refuse bins. • why they are generated. waste disposal invoices.e. You can obtain information on waste materials through: • getting material purchasing records. • where they are being generated. The objective of a waste audit is to profile the waste streams by finding out information on the • types of waste. but to identify the major waste and to provide a starting point for your waste diversion initiatives. The next step is to determine the true cost of dealing with the waste streams from various processes. prioritise efforts. This would help to provide a clearer picture of how much it costs the company when these waste are produced and then disposed of. If the operation of your company is a highly complex one that needs experienced personnel to conduct the audit. • storage containers to isolate. The suggested waste audit approach is not intended to provide a highly accurate and detailed measurement of all waste. 10 . you would have the basic information on the waste produced by your company. or the resources are limited in your company. operations. an estimate should be made of the resources required to carry out the audit. it can be seen that the true cost of waste is more than what meets the eyes. or labelled containers to identify waste from various generation points. reused / recycled / disposed ?): When conducting the waste audit. From the analysis of costs below.e. • space for sorting and storing waste during the audit. move. due to frequent machine break down): How it is managed after being generated (i. you may want to consider hiring consultants specialising in waste audits. and sort waste and recyclables. You can then identify the high cost waste streams. It can help to discover the root cause of wastage and identify solutions.g. • a weighing scale. Special attention needs to be given to find out why a waste is generated. or activities.Cost to manage and/or dispose: Why it is generated (e. • different-colour bags. Step 4: Determine the True Costs of Waste Having identified the waste streams and filled in the related information in the waste assessment sheets. There are two broad areas of costs that should be considered. tags. Your resources requirements may include the following: • adequate time for assigned people to carry out audit tasks to ensure the quality of your audit data. and track the overall success of the waste minimisation programmes. • Manpower costs o operating labour and supervision 11 . Some waste collectors may charge a company a flat fee to include all the three elements of the costs depending on the contract agreed upon. when we calculate the true cost of a waste. In its simplest form. o the raw material lost / leakage before it gets to the production process. this calculation should be made for each component. Container Rental Fee is the monthly fee for having a compactor. or refuse bins on-site. any business process involves many resources on top of the raw materials used. Simplest calculation of the true cost of a waste Cost of waste = Cost of raw material that + Cost of waste becomes waste disposal of = [Amount of raw material + Cost of disposal of raw material waste purchased – amount of raw material in product] x unit cost of raw material In reality. These three elements of the disposal costs may not apply in some cases. Disposal Tipping Fee is the charge for the amount of waste (tonnage) being disposed of at an incinerator or the landfill. Hence. Associated Costs The true costs of producing waste goes beyond the disposal cost. or an open top container. o the raw material in the rejects.Disposal Costs Hauling Charge is the cost you pay a contractor for collecting and transporting waste to an incineration plant or the landfill. and they can include the following: • Purchasing cost of raw materials o the raw material that exceeds the shelf-life. we need to add the cost of the raw material in the waste to the cost of disposal. we need to assign all the associated costs contributing to the true cost of producing a waste. Where more than one material is in the waste. The true cost of waste can be between 5 and 20 times the cost of their disposal. it is impossible to cover all aspects of costs associated with individual waste. Step 5: Develop Waste Reduction Options After conducting the waste audit and determining the true costs of waste. reduce waste and cut down costs. And in an average company. The true costs should be examined for each and every waste. the next step is to identify the opportunities to improve efficiency. it could be around ten times the cost of disposal.e. Although businesses have many elements in common. o managing waste-disposal contractors. 12 . seconds. True Cost of Waste = Associated Costs + Disposal Costs Experience has shown that many businesses spend around 4% of their turnover generating waste. o internal transport. In summary. downgraded product. the true cost of a waste should include all associated waste and the disposal costs. or an off-standard reject that can not be sold) • Cost of waste handling o storage.o o o o o maintenance work material handling inspection record keeping training • Utilities costs o electricity o water o steam o refrigeration o fuel o sewerage • Equipment depreciation • Loss of revenue (i. Objective Your objective at this step is to generate a comprehensive set of waste minimisation options. The waste minimisation techniques or practices listed below may help inspire you to generate ideas on options to reduce waste at your facility. Generally. These factors will be considered at the ranking of options stage later. The team should tap on all resources available and involve as many employees as practically possible. Other factors. an opportunity exists if a waste stream exists. Consulting staff from different departments. would be useful too. receiving/shipping (packaging waste) and office (paper. The team should not consider in detail the technical or economic aspects of any particular option. cartridge etc. general office waste). we can target at the higher cost waste streams as they may represent higher cost of raw materials. higher process inefficiency. Your suppliers / vendors and customers are also valuable resources. Much of the information needed can come from their education and on-the-job experience. such as purchasing officers. Prioritising waste streams If your company has quite a few waste streams. This will be done at the next step. and the payback period for high investment measures to reduce waste. and thus more potential for cost savings. These people know their working areas best and may be able to suggest good options for waste reduction. (1) Reduction of Manufacturing Waste (a) Inventory management 13 . General areas for waste reduction In general. can also play a part. Tapping on all resources Identifying potential options relies both on the expertise and creativity of the team members. One-way of ranking them is in terms of their true cost. we could identify options to reduce waste in three areas: manufacturing (raw material and process waste). The list may include several options for each waste stream or process. the working team should list all the possible opportunities of reducing waste within the facility. Most of the time. Consider all options At this stage of developing options. Consider every waste stream as a reduction opportunity until proven otherwise. you may want to prioritise them. engineers. such as whether the high waste cost can easily be reduced. machine operators and maintenance technicians. Material handling: • Ensure that raw materials reach the production process without loss through contamination. • Ensure that the material is efficiently handled and used in the production process and does not become waste. • develop review procedures for all materials purchased. • Encourage employees to separate waste that can be recycled from those that have to be sent for incineration or landfill. spills. Inventory control: • purchase only the amount of raw materials needed for a production run or a set period of time. It can be achieved or enhanced through modification in operational and maintenance procedures. (b) Production process modification Improving the efficiency of a production process can significantly reduce process waste generation. • Handle waste or rejects like a product. and the associated waste streams is an important waste reduction technique. Operational and maintenance procedures: • Look for opportunities to further improve efficiency of operational process procedures. to minimise the chances of storing them beyond their shelf-life period. and leaks. 14 . You may look for waste reduction options by observing some general guidelines described below. no matter how long they have been in operation or how well they have been run. Label and place recycling and trash bins in strategic locations of production process areas. • approach the suppliers to see if they can take back the excess materials. final products. material change and equipment. • purchase the material in the proper amount and the proper size container. Most production processes can be operated more efficiently. Experiences show that better inventory control and material handling could lead to reduction of raw material waste. intermediate products.Proper control over raw materials. Allowing a recyclable or clean waste material to be contaminated can reduce or eliminate its recovery potential. and make them part of the regular employee training programme. For example. and improve the process efficiency. to reduce waste generation caused by equipment failure. • Document fully improved operating procedures. 15 . and disposing of the cartridges have also been reduced. A high-technology and scientific equipment supplier uses employee teams to identify waste reduction opportunities. handling. • Use a less hazardous material in a production process where possible. • Look for ways to avoid contamination of a waste so that it can be put back into the originating process as a substitute for a raw material. they discovered one opportunity that now saves the company nearly $100. Material change: • Consider material change that will lead to the elimination of one step of the process. a paint manufacturer found that instead of using a series of coarse to fine filters to remove grit. • Look for ways to use a waste as a raw material in another process. which stresses preventive and corrective maintenance. The costs of purchasing. By changing the specifications for a steel-alloy part used in manufacturing seals. • Maintain a strict schedule on all maintenance activities under the programme and keep accurate records. and eliminating them will reduce waste generation. the company was able to purchase an alternative material which requires less cutting and shaping to meet the customers’ needs. • Consider material change that may have an impact on overall waste reduction.Some process steps may in fact be unnecessary. The company also realised substantial savings through a 66% reduction in metal waste. This could lead to elimination. the generation of spent filter cartridges was reduced by more than 50%. In the course of a discussion between an engineer and a purchasing expert. As a result of this change to using only one filter. Such a programme can help spot potential sources of release and correct a problem before any material is lost. only the fine filter was necessary. or reduction of raw material used and waste generated. Just this one material switch reduced their labour cost by 33% and other related costs.000 each year. • Implement a strict maintenance programme. For an investment of US$181. (2) Reduction of Packaging Waste The packaging materials usually include cardboard.Process equipment modification: • Modify existing or install more efficient process equipment to take advantage of better production technologies: New or updated equipment can usually process materials more efficiently. 16 . It also saved on the cost of 17 tonnes of raw materials. but occasionally failed to function. and shipping. plastics. This generates more packaging waste at your customers’ end. Under their “Machine Improvement Programme”. and all associated costs such as labour and energy costs. improved operational procedures and process equipment modifications are used together to improve efficiency. and drums. it generates more waste at your facility. Your packaging waste will be either from your suppliers. A simple low-cost solution to the problem was proposed by the team involved in the programme. and reduce costs and waste. If your suppliers use packaging materials more than necessary to supply you the goods. they started looking into how to improve the reliability of the process. A manufacturing company’s core business is to produce office furniture. Sometimes the modification of equipment can be simple and effective in improving efficiency. who deliver the materials you need for your production. Each mis-cut top had to be discarded. or use single-use packaging. This will reduce waste and costs. The mechanical sensors on a machine that cuts desk and table tops were reliable. As a consequence. reduce the amount of raw material used. the company saved 17 tonnes of marketable tops valued at US$8. They replaced the mechanical sensors with more reliable optical sensors. or in the form of packaging materials you use to pack and ship your products to your customers.950 each year. because they could not be repaired. the tops were sometimes cut out-of-square. the cost on waste disposal. and cut down the number of off-specification products or rejects. Using packaging materials more than necessary to pack and ship your products costs you more in purchasing. materials handling. and incurs more disposal cost to you if the packaging is not recyclable. In many cases. costs you more time to handle. each product (which might consist of several disks and manuals) was packed in a small corrugated cardboard box. they have achieved significant resource savings on packaging each year. packaging waste is often referred to as “low hanging fruit". Work with your suppliers and customers for opportunities to reuse and / or recycle packaging materials. these small boxes were then consolidated into one or more larger boxes. Thus. • reduce the use of packing materials. markets. Since many of its customers order more than one product at a time. then ships the 17 . A software company develops. They have created a "closed-loop system" for some transport packaging. So look into the ways to modify the design or change the material of packaging that can: • improve packing / shipping efficiency. manuals and disks are shrink-wrapped together. and / or • allow reusable or recyclable packaging. and ships computer software products that support software libraries for computer programmers and math experts.Many companies’ experiences have shown that the easiest area to begin waste reduction is most likely in the packaging area. in waste reduction. the company was able to create custom packaging to ship sheet metal parts. They have achieved financial savings (packaging only) of $21. Under the new system. eliminating the smaller boxes. By convincing a customer to use a local vendor for an interim manufacturing step. The second vendor inserts additional components. The company has implemented several waste reduction measures in its product packaging. An engineering company manufactures and assembles precision custom sheet metal parts for its customers. In addition.000/year. This has reduced the weight of packaging sent to customers by an estimated 68% and significantly reduced staff time. Below is one of the examples: Previously. • Ensure fax machines are set so that they do not produce unwanted headers or report sheets. reuse and recycling. Yet it is a cost that can be brought down easily through reduction. • Put reminder posters near printers and photocopiers. The durable cardboard packaging is returned to the company and is reused at least 10 times before being recycled. and which is general paper waste. (3) Reduction of Office Waste In a typical office. I can print DOUBLE-SIDED.completed assembly to the end customer. Encourage them not to print out e-mails unless absolutely necessary. Paper is therefore a major purchasing and disposal cost to the average office. Financial savings amounted to more than $50. • Use single-spacing for report or memo writing. • Reduce confidential waste costs by giving clear instructions to staff as to which material is strictly confidential. photocopying and publications are produced in double-sided format where possible. Ensure that your staff is comfortable with new technology and provide training where necessary. • Edit and proof-read carefully on the computer before printing. USE ME TO THE FULLEST!!! 18 . • Set narrower margins for drafts.000 a year. • Cancel subscriptions of unwanted publications to reduce paper waste. • Avoid overproduction of marketing and publicity material by reviewing distribution lists and regularly updating databases • Use electronic communication where possible to reduce printing and faxing. • Change margins to avoid the last page of your report with little text. The following suggested practical options could be considered to reduce paper waste in an office: Reduce • Make it a company policy that all printing. • Eliminate the use of fax cover sheet where possible. usually half of the total waste is paper-based. • Re-use envelopes wherever possible. Use recycled paper Paper is a natural resource that can be recycled up to about five times. especially for sending information internally. you can help boost the market for recycled products. and on bins explaining the types of paper that can be recycled. rubber bands 19 . Reduction of other office waste • Reuse paper clips. Place paper recycling bins in all office areas. Use paper ream lids as additional staff desk top collection trays. Suggest making a donation to charity or planting a tree when targets are met. • Promote the scheme to staff by putting up posters around the offices. Reuse • Collect all paper that has been printed on one side and re-use it for printing in draft or for scrap message pads. By using recycled paper. Where possible. • Ensure that cleaning staff are in support of the recycling scheme and that emptying the recycling bins is part of their contracted work. • Provide staff with on-going feedback about the scheme. and one next to each photocopier and printer. you may consider purchasing and using recycled office paper. • Reuse paper file folders.g.• Share newspapers / magazines. Recycle • Set up a waste paper collection system and send waste paper for recycling. This will in turn support the recycling industry and reduce unnecessary use of virgin materials. Today the quality of paper containing recycled fibre (e. This substantially reduces the impact on the environment. 51% recycled fibre) has improved and is comparable with virgin paper. including figures on the amount of paper collected. A good guide is one bin between six staff members. Step 6: Assess the Scope of Savings and Rank Options Having generated a number of options to solve a waste minimisation problem. the next step is to assess their feasibility.e. • Is this option appropriate to the problem (e. and whether there are any facility constraints or product requirements which will make it technically unwise to implement. The completed technical assessment should be reviewed by all affected sections / departments / divisions of the company. and whether they can recover transportation cost. It is also to assess the scope of savings of options. The costs are much lower. installing automatic controls where a simple change to operating procedures would be just as good)? • Who can implement this? (i. • Does the change meet shipping / packing criteria to protect the products from damaging.g. is there convincing evidence that the option will work as required? • Is the option compatible with the current manufacturing process. 20 . • Purchase re-manufactured print cartridges from cartridge recycling companies. During the screening procedure to assess the options. and rank and decide the options that can be implemented. depending on the quantity and model of the cartridges.• Collect print cartridges for recycling. • Does the change maintain product quality requirements. (a) Technical Assessment Technical assessment is to determine whether a proposed option will work. Some local recycling companies can pick up and buy back the used cartridges from you. the following questions can be asked by the team to facilitate the assessment: • Does the proposed option of equipment / technology change have a good track record in the market? If not. and you could look for the companies that can provide you warranty on the re-manufactured cartridges. and a range of options for various waste streams. Is external help needed or can it be done inhouse?) • When can it be implemented? Some solutions may take longer than others to come to fruition. • on-going cost of operating or maintaining the solution (i.e. an option that reduces or eliminates waste is better than a recycle route identified for the waste)? 21 . There is also a UK guide available which can be found at this website (www. (b) Economic Assessment An economic assessment of a potential solution to a waste minimisation problem includes: • one-off cost of implementation (i.e. In some cases. Calculating payback The payback can be calculated by dividing the total one-off cost of the project by the net saving of the project (the difference between savings and operating & maintenance costs).gov.uk/envirowisev3. costs of design. running costs. • savings from the associated costs (i. These could include undiscounted and discounted financial analysis.envirowise. The waste minimisation working team could approach the company accountant if there are any doubts about calculating cost and benefit. (c) Other Considerations Other factors that could be considered include: • How much waste could be reduced through the change? • Is the option easy to implement? • Does the option ensure the lowest environmental burden or impact compared with other options (e.g. more in-depth assessment methods may be required. testing and implementation). In many cases a simple payback calculation is sufficient to assess the economic feasibility of an option or to identify an optimum option. This gives a payback figure in years.Any options that are deemed to be technically feasible now require economic assessment. It contains detailed examples of financial appraisal. capital investment.e. raw material cost and other relevant costs listed in step 4) and disposal costs. maintenance costs).nsf/key/GuidesP) called “Investing to Increase Profits and Reduce Waste”. you can start to develop and write a waste minimisation plan for your company including: • Targeted waste streams for reduction. • Training of personnel involved.• Does the option ensure that the change will not create problems in other environmental areas (e. Step 7: Develop a Waste Minimisation Plan What to be Included in a Waste Minimisation Plan When the tasks outlined in the previous steps are completed. • Estimated volume of waste reduction (i. the decrease of solid waste does not increase liquid waste or hazardous waste)? The overall assessment based on the technical and economic assessments. • Implementation schedule of the options (steps or phases and timing for implementation). • Measurable. Summary of waste minimisation plan Waste type Qty (t/ kg) Proposed option for waste reduction Waste reduction goal (t/kg) Estimated costs Estimated payback period Start End date date Status 22 . • Implementation requirements (such as tasks and personnel assignments). kg) for each waste stream.e. • Proposed options to minimise the waste and a description for each option. performance goals • Target dates for completion of goals In addition to the write-up of the plan. • Estimated costs involved. and considerations of the factors listed above should lead to the final ranking of the most reasonable options for reduction of waste streams. you could create a summary table of the plan similar to the one below for ease of reference for your team and the management. • Management requirements. • Estimated payback period and net savings.g. specific performance goals need to be established and expressed in numeric terms. • The programme's actual costs and savings compared with the initial programme estimates. * Obtaining good quality data for waste stream volume. The following are some useful measurements for setting the waste and cost reduction goals: • Ratio of waste generated to production rate. • Changes in utilities and maintenance costs. you could schedule such options like operation procedural changes or material changes for implementation as soon as possible. • Savings on raw materials costs and waste disposal costs. • Changes in manpower and other associated costs. design. Thus. procurement. or kilograms of waste generated per standard unit of production. before and after implementation of the option. it would be more meaningful to measure it in terms of actual waste reduction in tonnes. and you may need to schedule them for implementation at a later stage when resources are available and the team can cope. So you may wish to schedule the easy options first. flow. which do not involve equipment change. Establishment of Goals & Measuring Indicators In order to measure the success of the waste minimisation plan. construction or installation. and composition can be costly and time consuming. the options that have shorter payback period and produce greater savings can be scheduled for implementation early.Considerations for Scheduling the Implementation: Packaging usually provides the easiest reduction opportunities and thus the greatest potential for savings. The phases of the project include planning. In waste minimisation plans that call for equipment changes. it's essentially the same as any other capital improvement project. in some instances. For this reason. • Changes in production capacity and product quality. Also. To measure waste reduction. are inexpensive and quick to implement. • *Ratio of raw materials consumed to production rate. before and after implementation (an indirect measure of waste reduction). expressing waste reduction indirectly in terms of the “ratio of input materials 23 . Some options. • Suitable to the overall corporate goals. Assign clear responsibility and authority to appropriate personnel in all administrative. Step 8: Implement and Improve the Plan When the waste minimisation plan is firmed up. The following measures could be used for creating awareness: • Launch the waste minimisation plan by the CEO or Managing Director of the company. • Display the plan and the implementation schedule with explanation of waste reduction goals in prominent locations. the team should be clear about the goals and objectives of the plan. and • Achievable with a practicable level of effort. several important actions are needed to ensure success. • Put up educational posters in strategic locations. At this stage. include a clearly stated list of actions designed to lead to the establishment of numeric goals as soon as possible in your waste minimisation plan. • Measurable over time. 24 . When using suggested measurements to set the waste reduction goals. At the same time. • Organise waste minimisation educational talks for staff in training sessions. the team should develop a waste minimisation awareness programme to get the key messages across to all employees and gain their support. These data are easier to obtain although the measure is not direct. If the establishment of numeric performance goals is not practical. the team need to try to set the goals that are: • Understandable • Acceptable to those who will work to achieve them. operating and maintenance areas. • Flexible to adapt to changing requirements. Make the right resources available.consumption to production rate” may be more practical. the implementation is the key. Firstly. and ensure that the personnel take implementation actions according to schedule. More action might be needed or different methods might become available. • Share and update waste reduction results periodically with all employees. and training. WASTE MINIMISATION CASE STUDIES Baxter Healthcare Pte Ltd Chevron Oronite Pte Ltd IBM Singapore Pte Ltd Kyoei Engineering Singapore Pte Ltd Sony Display Device (Singapore) Pte Ltd Tetra Pak Jurong Pte Ltd 25 . and using the resource information listed in References section. • make on-going improvements. ideally upwards. and contribute to solving Singapore’s waste disposal problem. By following the steps in this guidebook.• Prepare waste minimisation tips for individuals to take action and make them available to staff through emailing and notice board. So you need to: • make changes to the planned actions and adjust operating procedures. To ensure a sustainable programme. and • set reviewed waste reduction goals. the team should: • make all implemented options or measures a functioning part of a company's standard operating procedures. operational procedures. • incorporate new options or methods. • establish new priorities for action. The team need to monitor waste reduction performance against the goals established and conduct annual reviews to compare the current performance with the pervious year. it is hoped that your company can achieve sizable cost savings and waste reductions. During the process. Include product development. additional waste reduction opportunities might arise. with assistance from the Minnesota Emergency Response Commission (ERC)]. UK. August 1996 (Revised) Minnesota Guide to Pollution Prevention Planning [Joint effort of the Minnesota Technical Assistance Programme (MnTAP) and the Minnesota Office of Environmental Assistance (OEA). and Todd Logsdon (Engineering Associate). Kevin McDonald (OEA). University of Louisville. UK. 1999 Waste Minimisation – An Environmental Good Practice Guide for Industry. John Polanski (MnTAP). 1999 (2ND Edition) The Measure of Success – Calculating Waste Reduction WasteWise Update. Commercial and Institutional Sectors Ministry of Environment and Energy.END ---- 26 . UK. August 1995 Green Officiency: Running A Cost-Effective.REFERENCES A Guide to Waste Audits and Reduction Workplans for Industrial. Kentucky Pollution Prevention Centre. Published by the Environment Agency. Staff Team: Kenneth Brown (OEA). EPA. University of Louisville. Keith Ridley (Assistant Director of Assessments). Cindy McComas (MnTAP). July 1999 No Time to Waste – a practical guide to waste minimisation Scottish Environment Protection Agency. Revised edition April 2001. Envirowise. David Cera (OEA). 1999 Where are the Biggest Cost Savings? WasteWise. US. Environmentally Aware Office. 2002 Industrial Solid Waste Reduction Workbook Prepared by: Cam Metcalf (Executive Director). Mark Snyder (OEA). ---. US Environmental Protection Agency. Authors: Robert Lundquist (MnTAP). First published April 1998 Waste Minimisation and Recycling Guide (Covering the North East Regional Development Area) Environment Agency. Canada. Ontario. 1995 Developing a Pollution Prevention (P2) Plan: A How-To Book for Kentucky Generators Published by The Kentucky Pollution Prevention Centre (KPPC).
Report "Guidebook on Waste Minimisation for Industries"