UNIDOUNIDOTEST MethodologyTEST Methodology

Carolina GonzalezCarolina Gonzalez29 October 201329 October 2013Nairobi, KenyaNairobi, Kenya

Solutions Forum IIClean Technologies for

Green Industry

OutlineOutline

1. TEST Methodology

2. Case studies & Results - MED TEST project

3. Replication & Up-scaling

Green IndustriesGreen Industries

Green Industries means economies that strive for a more sustainable pathway of growth, by undertaking green public investments and implementing public policy initiatives that

encourage environmentally responsible private investments.

www.unido.org/greenindustry

Decoupling resource depletion from economic growth

Transfer of Environmentally Sound Transfer of Environmentally Sound Technologies - Technologies - TEST MethodologyTEST Methodology

Objective: Support sound management of resources use at priority industrial hot spots, to minimize use of resources and maximize productivity through the demonstration of best practices, application of clean technologies, and capacity building.

The methodology demonstrates that industries can achieve economic benefits through the application of best environmental practices and resource efficiency.

TEST Global Application TEST Global Application

Context

The TEST integrated approach was developed by UNIDO in 2000, it was implemented in 5 countries in the Danube River Basin.

The TEST methodology aims to improve environmental management and competitiveness of companies (primarily SMEs) in developing countries and economies in transition.

TEST consists of five management tools aimed at changing practices in industries/companies in a comprehensive way in order to ensure the adoption of environmental practices.

The 5 Tools of TESTThe 5 Tools of TEST

Resource Efficiency and Cleaner Production (RECP)

Environmental Management Systems (EMS)

Environmental Management Accounting (EMA)

Environmentally Sound Technologies (EST)

Corporate Social Responsibility (CSR)

Initial Review

Phase 1 RECP, EMS, EMA

Phase 2 EST

Phase 3 SES/CSR

TESTTEST:: major steps major stepsPotential for improvement

Viability and commitment

EMA – total costs of material losses

RECP – BAT/BEPs

EMS – system support

Investment needing measures

Feasibility study, Financing

Evaluation and reflection

Sustainable Enterprise Strategy

Fundamentals of TEST programmeFundamentals of TEST programme

√ Integrated approach that links sustainability to core business strategy, management systems and manufacturing processes

√ Benchmarking company performance with ratios/technology in the global market

√ Training, Monitoring, Follow up & Top management engagement

√ Multidisciplinary skills and Technical sectoral expertise √ Flexible approach depending on company size and baseline,

applicable at existing sites and for start-ups√ Linking to existing financing investment schemes (SMEs)

MED – TEST ProjectMED – TEST Project Overall Objective: Build national capacities in UNIDO-TEST

integrated approach and conduct pilot projects within priority industrial areas affecting the Mediterranean basin to demonstrate the economical/environmental benefits of resource efficiency and sustainable production.

Countries: Tunisia, Morocco and Egypt Funding: 2.1 M USD - GEF, Italian Government Coverage: 43 industries, 7 industrial sectors Duration: 2009-2012

www.unido.org/medtest

Selection of companiesSelection of companies

Company participation is voluntary Industry motivation to join TEST: productivity and

cost reduction, pressure from supply chain and customers, regulatory compliance

Cash Co-financing from companies required (ownership)

Selection criteria: Management commitment Environmental problems &

potential for improvement Financial viability - creditworthiness

Components & outputsComponents & outputs

Capacity Building

Pilot Demonstrations

Dissemination & Replication

Components Outputs

Network of national resources, institutions and service providers trained and experienced in implementing TEST integrated approach in industry.

• Best practices introduced with economic benefits

• Reduction of pollution discharges• Investment portfolio for cleaner technology

transfer tapping existing national financial instruments

• National and Regional dissemination of best practices and lessons learned• National replication roadmaps and kick off of commercially based TEST application in new companies

Priority SectorsPriority Sectors

Tunisia: Agro-food, Textile, Leather Morocco: Agro-food, textile, Metal, Ceramic Egypt: Agro-food, Chemical, Pulp & paper

Metal; 3

Leather; 4Chemical; 6

Textile; 8

Ceramic; 2Food &

Beverage; 16

Pulp & Paper; 4

RECP: Types of measuresRECP: Types of measures

Water conservation: cleaning techniques, in process recycling and second grade applications (water treatment units); monitoring & use of meters

Product recovery & valorisation: product push before CIP, in process recycling, off specs & returns from clients, packaging, valorisation of by-products

Steam generation and distribution: insulation, fuel switch, process integration

Electric system: power factor, compressors, optimisation and heat recovery of chillers, cold storage rooms, lighting

Project’s achievements in industries

Number of measures implemented, retained for study, discarded

0 100 200 300 400 500 600 700

Implemented

Retained for study

Discarded

Return on investment of identified measures

54%

23%

23%

0<PBP<0.5 yr 0.5<PBP<1.5 yr 1.5 yr<PBP<4 yr

MED TESTMED TEST

Case Studies & Results

Company Cap-Bon (SCAPCB) Company Cap-Bon (SCAPCB) Case study: Food Sector

SCAPCB produces canned food. It has a daily production capacity to process 1,200 tons of fresh tomatoes.

Measures identified: • Company designs: modification of the nozzle used for pre-rinsing and final rinsing of fresh tomatoes, reduced the overall water consumption by 40%. It also improved the overall quality of finished products.

• Valorization of by-products: waste from tomato refinement sold to farmers to enrich animal fodder

• New equipment: installation of a water tank (300 m3) allowed for a more efficient distribution and use of well water and protects submerged pumps against water currents.

Overall water savings of 129,737 m3/yr.

Société Moderne des Cuirs et PeauxSociété Moderne des Cuirs et Peaux (SMCP) (SMCP)Case study: Leather Sector

SMCP is a leather company founded in 1965. Production is distributed in ovine skins (57%, 525 tons/year), goat skins (10%, 90 tons/year) and bovine skins (33%, 300 tons/year). It produces for both local and international markets.

Measures identified: • Reuse of chemicals: recovering chromium sulphate after precipitation and filtering can replace 46% of the new chromium with no impact on the quality of finished leather. This allows for the reuse 24 tons/yr of recovered chromium otherwise discharged as sludge

• New equipment: A change to perforated shaking drums facilitated the elimination of salt from the salted hides. This resulted in the elimination of 120 tons/yr of salt and a 40% reduction of chlorides in the wastewater.

GARTEX GARTEX Case study: Textile Sector

GARTEX is a jeans production and bleaching company fully focused on exports, with a working capacity of 2,800,000 items/yr.

Measures identified: • Adaptation of equipment: their washing machines were equipped with double water exits, which facilitates the implementation of a system for reuse of rinse water. By installing a network of gutters, pipes and water pumps 11,250 m3 water can be saved annually.

• Change in programming: An automated programming was put in place which establishes general washing and drying programmes, as well as sub-programmes to facilitate adjustments, thereby eliminating manual interference and reducing error risk. The change reduced water consumption by 25% (3.500 m3/yr), thermal energy (162 MWh/year) and chemical products (6%).

Results: Egypt

Company Size (*)

Investments [USD/ yr]

Savings [USD/ yr]

Water Savings

[%]

Energy Savings

[%] Food & Beverage Sector Edfina Company for Preserved Food 660 257,518 889,000 32 3 Egyptian British Company for Development (Galina-Agrofreeze)

200 75,540 414,956 50 6

Egyptian Company for Starch, Yeast & Detergents 1,130 136,474 1,696,132 40 44 El-Nile Soft Drinks Company (Crush) 1,000 1,564,086 1,264,042 85 19 Chemicals, Petrochemicals and petroleum sector Extracted Oils and Derivatives Company 2,300 429,627 127,803 18 1 Misr Chemicals Company (MCI) 740 49,033 416,057 26 7 Solvay Alexandria Sodium Carbonate 700 97,050 466,793 17 10 Egyptian Petrochemicals Company (EPC) 3,300 1,536,667 530,638 4 35 Misr Petroleum Company (Lube Oil Blending Plant) 430 100,934 457,371 20 8 Leather sector, tanneries Atef El Sayed Tannery 40 416,850 97,377 30 47 Pulp and paper sector General Company for Paper Industry (RAKTA) 1,125 2,443,446 1,518,446 15 10 Moharrem Press Company 940 279,217 304,786 33 15 National Paper Company (NPC) 920 1,731,170 1,228,167 52 12 TOTAL 9,117,614 9,407,568

Results Morocco

Company Size (*) Investments [USD/ yr]

Savings [USD/ yr]

Water Savings [%]

Energy Savings [%]

Food Sector Fromagerie BEL (dairy) 500 280,328 333,830 20 7 Colainord (dairy) 600 117,929 381,436 23 13 Cumarex (fish) 320 131,099 168,148 10 20 C2M (fish) 350 120,175 73,970 22 65 BOA (meat) 320 79,125 133,500 48 26 Textile Sector, finishing Ecolorentel 400 324,327 242,041 4 7 Lavesma 300 250,911 474,615 2 27 Metal Sector Aluminium du Maroc 200 262,164 370,431 7 11 Industube 90 85,800 327,375 1 12 Ceramic Sector Ghorghiz 200 347,538 433,180 80 4 Ceramica Dersa 50 87,125 205,306 80 12

TOTAL 2,086,566 3,143,814

Results Tunisia

Company Size (*)

Investments [USD/ yr]

Savings [USD/ yr]

Water Savings

[%]

Energy Savings

[%] Food & beverage Sector Générale Industrielle Alimentaires Slama (GIAS) 493 191,200 133,700 12% 17% Société de Conserves Alimentaires du Cap Bon 50-250 98,139 73,639 44% 9% Tunisie Lait 308 827,410 746,638 16% 13% Société de Boissons du Cap-Bon (SBC) 119 56,331 75,454 22% 21% Societè Nouvelle de boisons 202 29,200 194,600 12% 14% Centrale Latiere du Cap nord (CLC) 547 484,945 546,903 13% 19% Textile Sector, finishing Teinturerie et Finissage Mediterraneenne (TFM) 55 76,500 55,600 10% 30% Gartex 185 181,800 111,836 19% 39% Megastone 150 139,000 91,300 24% 7% Traitex 60 37,500 28,800 30% 14% Garment Dyeing Service 80 1,264,645 491,860 56% 10% Star Wash 40 76,200 67,200 19% 15% Leather Sector, tanneries Tanneries Megisserie du Maghreb (TMM) 180 523,000 446,800 14% 15% Société Moderne des Cuirs et Peaux (SMCP) 35 287,000 97,200 22% 3% Tannerie du Nord Utique 50 184,000 125,000 8% 70%

TOTAL 4,456,870 3,286,530

MED TEST - Achievements

Key figuresKey figures 6 National partners/service providers 30 TEST Trainees 43 Demonstration industries 958 Man days of training delivered to industry and trainees

Results Industry Demonstrations:16 Millions USD/yr economic savings9,600,000 m3/yr water savings250,000 MWh/yr energy savings

Donor funds, 2.1 M USD, leveraged 20 M USD of private sector investment

Funding: 17 M EUR, from the European Commission Partners: UNIDO, CPRAC, UNEP-MAP & UNEP-DTIE Countries (9): Morocco, Tunisia, Egypt, Lebanon,

Palestine, Jordan, Israel, Algeria and Libya. Duration: 4 years (2014-2018)

Replication & Up-scalingReplication & Up-scaling

SWITCH-Med Demonstration and Networking Components

SWITCH-Med SWITCH-Med The objective of the SWITCH-Med is to facilitate the shift toward

Sustainable Consumption and Production (SCP) in the Southern Mediterranean Region.

The SWITCH-Med umbrella programme consists of 3 Components: Policy, Demonstration and Networking.

Demonstration Component: Sustainable production - MED TEST II Green entrepreneurship and civil society empowerment SCP Nation Action Plans demo

Networking Component

Facilitate networking & knowledge sharing among partners, and foster lessons learned

THANK YOUTHANK YOU

Carolina Gonzalez

Environmental Management BranchWater Management Unit

C.Gonzalez-Castro@unido.org