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Pilot Project Chemical Safety by Susanne Scholaen Tulpenfeld 2, 53113 Bonn, Germany Tel: +49 228 9857015 email: [email protected] web: www.gtz.de/chs/

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Pilot Project Chemical Safety by Susanne Scholaen Tulpenfeld 2, 53113 Bonn, Germany Tel: +49 228 9857015 email: [email protected] web: www.gtz.de/chs/. Pilot Project Chemical Safety. By order of the: Federal Ministry for Economic Cooperation and Development (BMZ)

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Pilot Project Chemical SafetybySusanne ScholaenTulpenfeld 2, 53113 Bonn, GermanyTel: +49 228 9857015email: [email protected]: www.gtz.de/chs/

pilot project chemical safety
Pilot Project Chemical Safety

By order of the:

Federal Ministry for Economic Cooperation and Development (BMZ)

in technical cooperation with the:

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

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pilot project chemical safety1
Pilot Project Chemical Safety

Provides assistance to developingcountries or countries with economies in transition:

  • In the framework of Agenda 21, Chapter 19 on the sound handling of chemicals
  • In the implementation of the Rotterdam (PIC) and Stockholm (POPs) Conventions.

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Chemical Management Guide

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

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The Chemical Management Guide was elaborated and published by GTZ-Pilot Project Chemical Safety in close cooperation with:
  • The bilateral Indonesian-German Project ProduksiH which is counseling small and medium sized enterprises in the wide field of cleaner production and good housekeeping.
  • The Pilot Programme for the Promotion of Environmental Management in the Private Sector of Developing Countries (P3U) who developed guides in the area of good housekeeping and environment-oriented cost management.
  • German Federal Institute for Occupational Safety and Health.
  • Tool 1 of the Guide is based wholly on the approach of the ILO Safe work chemical control Toolkit 2001, produced by the Geneva-based International Labour Organization working in collaboration with the International Occupational Hygiene Association (IOHA) and Health and Safety Executive (HSE) in the UK.

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objectives
Objectives

Enabling the companies to:

  • implement a framework for effective and preventive Chemical Management
  • move in the direction of continuous improvement

It does not replace legal requirements!

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target groups
Target groups
  • companies where chemicals represent amajor portion of their running costs
  • industry associations, business chambers
  • management consultants
  • institutions doing private sector promotion and/or environmental policy

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methodology
Methodology
  • Tool for developing countries:
  • Easy to understand and to apply
  • Show incentives – make them take the bait
  • Convincing that improvement is not expensive
  • Demonstrate that international standards are achievable
  • Show the benefit

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benefits

Reducing production costs

Improving worker health and safety

Triple win

Reducing environmental impact

Benefits

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flow of chemicals in an enterprise

Purchase

Output in product

Output as waste (solid, in the water, in the air)

Flow of Chemicals in an Enterprise

Delivery

Storage

Handling and transfer

Processing

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methodology1
Methodology

Step by step implementation

Step 1 – Identify “hot spots”

Step 2 – Make a comprehensive chemical inventory

Step 3 – Make improvement continuously

5 Tools to help implement step 1 - 3

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step 1 identify hot spots
Step 1- Identify hot spots

Walk through your company and make observations

  • Identify places of inefficient storage, handling, use and disposal of chemicals
  • Identify particularly hazardous situations where potential harm could be reduced or prevented – spotting waste, losses and risks.
  • Develop Action Plan

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mapping out of hot spots

chemicals in

waste bins

Chemicals stored at Working Place

Courtyard

Chemicals stored

old containersof chemicals

Production Area

Office Area

Transport Area of Chemicals

Chemicals in the Production Process

Filling and bottling of chemicals

Main Storage of Chemicals

Storage Area

Chemicals in Waste Water

Chemicals Delivery Area

Mapping out of hot spots

Ground-Plan of the company

Stored Chemicals

Transport and Handling of Chemicals

Processing of Chemicals

Output of Chemicals

action plan
Action Plan

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general observations from test implementation in five companies
General observations from test implementation in five companies

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

  • powdery dyestuffs should be replaced with granular or liquid dyestuff
  • drums containing solvents should be covered
  • appropriate tools and protection gear should be provided to workers
  • only products should be purchased by the companies, which are properly labeled, transfer containers within the production process should be labeled also.
  • companies should insist on provision of MSDS.

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smooth and shiny leather tannery
Smooth and shiny leather tannery

Tannery

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

Family business

Approx. 60 people in one shift

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smooth and shiny
Smooth and shiny

Identified HOT SPOTS and priorities within the Action Plan

  • Repair leaking roof in the beam house
  • Keep only the materials needed for daily use in the production
  • Create central storage area for dyestuffs with proper management
  • Stop selling green flashings for reuse in padang
  • Improve handling of dyestuffs and hazardous chemicals
  • Improve safety standard in the lab
  • Avoid that chemical containers are used for bathing and drinking water for workers
  • …..

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blue velvet success story
Blue Velvet Success Story

Blue Velvet Textile Company

  • family-run company in Bandung, Indonesia established since 1978,
  • employing 185 people working on 3 shifts per day,
  • operates as a job shop, dyeing and printing polyester and produces rayon,
  • production is destined for both local and export markets.

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blue velvet success story1
Blue Velvet Success Story

Main recommendations from applying the

Chemical Management Guide:

  • Reduce waste of dyestuffs in sampling
  • Improve handling of substances in the emulsion kitchen to avoid losses, expiry, and contamination
  • Identify substances that are particularly hazardous and look for substitutes
  • Remove chemicals not in immediate use from the working areas of the factory as much as possible
  • Ensure each department has a complete stock list

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Step 2 –

Make a comprehensive chemical inventory

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smooth and shiny inventory1
Smooth and shiny inventory

Benefits from the inventory:

  • Provides information on the danger and risk of chemicals
  • Enables the companies to search for replacements – less dangerous and/or less costly materials
  • Gives possibility to monitor the use of the products – improvement of efficiency in material utilization
  • Ensures proper management within the company, dangerous chemicals can be treated appropriately.

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Step 3 – Make improvement continuously
  • Continue inventory and implementation of improvements
  • Replace dangerous chemicals for less toxic ones
  • Evaluate actions undertaken to determine if the set of objectives have been achieved
  • Communicate and reward results
  • Monitor results to ensure that improvements are maintained
  • Establish new target and areas for action in order to make further improvements in the company’s operations.

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tools to help you achieve steps 1 2 and 3
Tools to help you achieve steps 1, 2 and 3
  • Basic concepts for doing risk assessment
  • Description of control approaches
  • Using MSDS

4. Risk Phrases for hazardous substances

5. Safety Phrases for hazardous substances

6. Symbols used for labeling hazardous substances

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further activities
Further activities

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

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

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

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The Chemical Management Guide is available in different languages:
  • English
  • Bahasa Indonesia
  • Spanish (in process)
  • French (in process)

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