Pilot Project Chemical Safety by Susanne Scholaen Tulpenfeld 2, 53113 Bonn, Germany Tel: +49 228 9857015 email: gtzscho

1. Pilot Project Chemical SafetybySusanne ScholaenTulpenfeld 2, 53113 Bonn, GermanyTel: +49 228 9857015email: gtzscholaen@aol.comweb: www.gtz.de/chs/

2. 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) IPCS Geneva

3. 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. IPCS Geneva

4. Chemical Management Guide Improve Chemical Management to Gain Cost Savings, Reduce Hazards and Improve Safety IPCS Geneva

5. 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. IPCS Geneva

6. 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! IPCS Geneva

7. 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 IPCS Geneva

8. 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 IPCS Geneva

9. Reducing production costs Improving worker health and safety Triple win Reducing environmental impact Benefits IPCS Geneva

10. 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 IPCS Geneva

11. 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 IPCS Geneva

12. 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 IPCS Geneva

13. 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

14. Action Plan IPCS Geneva

15. 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. IPCS Geneva

16. Chemicals stored in production area IPCS Geneva

17. 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 IPCS Geneva

18. 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 • ….. IPCS Geneva

19. Cuttings of flashings are sold to restaurants to make crispy pork skin IPCS Geneva

20. Green flashings sold for making of crispy pork skin IPCS Geneva

21. 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. IPCS Geneva

22. 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 IPCS Geneva

23. Action Plan Recommendation 1 IPCS Geneva

24. Action Plan Recommendation 2 IPCS Geneva

25. Action Plan Recommendation 3 IPCS Geneva

26. Action Plan Recommendation 4 IPCS Geneva

27. Step 2 – Make a comprehensive chemical inventory IPCS Geneva

28. Smooth and shiny inventory

29. 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. IPCS Geneva

30. 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. … IPCS Geneva

31. 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 IPCS Geneva

32. 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. IPCS Geneva

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

34. Mixing of dyestuffs without protection IPCS Geneva