Pharmaceutical Technologist - July 2008 - (Page 21)

Reducing waste water the time to present the review and potential savings to gain their full support. Step 5: consider improvement options After establishing which areas are particularly problematic and the likely causes, the next stage is to identify and evaluate possible improvement options. This can be done by eliminating excess water usage, reusing water where possible, recording costs and savings from possible reduction measures, and involving staff in the decision making and implementation process to ensure the workforce is committed to the programme. Do not be put off by established practice. There could be many opportunities raised by independent questioning. Sometimes, simple measures may prove effective such as rotameters and valves making it obvious whether water is being used or not. Question whether there is scope for using the process waste water for non-process lines; for example, why is the exhaust air scrubber left operating when there is no load on it? Step 2: appoint a champion and establish a team It is useful to have an overall project coordinator or champion to lead and facilitate the work. The champion should be someone with: ● Authority, or sufficient access to an authoritative figure. ● A good understanding of how the company operates in all areas. ● The ability to listen to others and make objective decisions. ● An enthusiasm for the environment and waste minimization. In most companies, the responsibilities for using water and the impact of waste are spread across a number of departments. Therefore, a team should be established that includes environmental, health and safety staff, manufacturing/production managers and ‘shop floor’ staff to be called on as and when necessary. the measures being taken, and the progress being made through newsletters, notice boards and team briefings. Many companies run internal environmental campaigns through a marketing type approach and this is an excellent way of involving staff at all levels. Step 8: review progress Review the process against targets regularly — perhaps first on a 6 monthly-basis and then on a yearly basis. It may also be helpful to review the effectiveness of the process monitoring and data gathering, as well as the success of the team itself, which will in turn help inform future endeavours. One area that should not be overlooked by companies is ‘domestic’ usage. Case study Step 3: gather information Understanding where water is used and why effluent is generated is essential for improvements to be targeted; for example, the overall site use of mains water can be determined by looking at meter readings, but additional meters to monitor key processes and particular products can also be installed. Conducting a mass balance to estimate the cost of ‘unknown’ water losses — typically through leaks and evaporation — can also help companies to monitor the water used in processes. Water should also be monitored in key products and processes to identify and deal with the causes of waste, which enables greater accountability and ‘buy in’ of individual departments. Step 6: produce an action plan Having considered the various options, prepare an action plan that sets out the various problem areas, the proposed priority measures, and the achievable targets and timescales. At this stage, it is important to seek senior management approval, and that the plan and its benefits are communicated to staff. Step 7: implement the action plan Implementing the action plan involves teamwork. To maintain interest and motivation, it is vital to keep staff at all levels informed of One pharmaceutical manufacturer recognized the business case for addressing water consumption in their operations early on and, through the implementation of a systematic programme of water reduction, achieved savings of approximately £50000 (€63075) during 2 years. The plant was a serious water-user with a daily consumption equivalent to that of 600 households. The company saw that the cost of water was much more than the £1 (€1.3) per tonne purchase price, as the purification process added an additional £10 (€12.6) per tonne. The washing of a polymer product On the go ● Step 4: analyse data and investigate potential problems The data gathered should be examined and analysed with a view to improving efficiency and saving money. Recording this information by tonne of product is the best method as it eliminates variations caused by changes in production. ● ● ● Manufacturers that have never examined their water consumption can make savings of 30% on water and effluent bills. Reducing water use offers improved productivity and a reduction in operating costs coupled with environmental credentials. Some improvement options include reusing water and eliminating excess water. Vessel washing is one of the largest areas of water use in the pharmaceutical sector, but there are many ways to optimize this process. www.ptemagazine.com 21 http://www.ptemagazine.com

Table of Contents Feed for the Digital Edition of Pharmaceutical Technologist - July 2008

Pharmaceutical Technologist - July 2008 Contents Industry Highlights Morpheus Market Watch Overcoming the Barriers The Tide of Change Eight Steps to Improved Water Efficiency Q&A

Pharmaceutical Technologist - July 2008

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