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Acknowledgments
This report has been prepared as part of the EPAs Science, Technology, Research and Innovation for
the Environment (STRIVE) programme 20072013. This programme is administered on behalf of the
Department of the Environment, Heritage and Local Government by the Environmental Protection
Agency which has the statutory function of co-ordinating and promoting environmental research. The
programme was financed by the Irish Government under the National Development Plan 2007-2013.
The personnel involved in the production and preparation of this report were Lisa Sheils, Sandra Kavanagh
and Shane Colgan (EPA).
Disclaimer
Although every effort has been made to ensure the accuracy of the material contained in this publication,
complete accuracy cannot be guaranteed. Neither the Environmental Protection Agency nor the author
accepts any responsibility whatsoever for loss or damage occasioned, or claimed to have been occasioned,
in part or in full as a consequence of any person acting or refraining from acting, as a result of a
matter contained in this publication. All or part of this publication may be reproduced without further
permission, provided the source is acknowledged.
Cleaner Production
The Cleaner Production Section of the EPA STRIVE Programme addresses the need for research in Ireland to
inform policymakers and other stakeholders on a range of questions in this area. The reports in this series
are intended as contributions to the necessary debate on cleaner production and the environment.
www.epa.ie/researchandeducation/research/cgpp/
www.cleanerproduction.ie
www.epa.ie/whatwedo/resource/begreen/
www.nwpp.ie
Green Business:
www.greenbusiness.ie
ISBN: 978-1-84095-440-1
Price: Free
Foreword
The quality of Irelands environment is centre to our economic recovery, to job creation and the health
and well-being of the Irish people. On the economic and jobs front, environmental quality underpins key
elements of our national recovery strategy. Good environmental quality is central to our reputation and
growth potential in sectors such as food, drink and tourism.
There is growing demand both nationally and internationally, for environmentally sound products and
services, with increased pressure from green consumers, legislative requirements, producer responsibility
schemes and through stricter supply chain requirements from clients.
Irish organisations and companies are leading the way in environmental responsibility, showing their
commitment by participating in programmes such as the EPAs Cleaner Greener Production (CGPP) &
BeGreen programmes. Through these programmes, the EPA assists Irish enterprises and organisations to
improve their environmental performance, resource efficiency and eco-innovation.
The CGPP is a competitive and successful programme and was highlighted as an Exemplar Programme
by the European Commission in a review of Eco-Innovation. Alongside other State agencies, such as
Enterprise Ireland, SEAI and IDA etc. the EPA continues to encourage the business sector to move towards
cleaner greener production.
This report provides an overview of innovative and cost effective projects carried out across a range of
Irish business sectors under the EPAs CGPP. I hope that other businesses will learn from these success
stories and work towards the CGPPs overall objective: Better Business in a Better Ireland.
Laura Burke
Director General
Contents
Foreword
Introduction
10
11
11
12
12
Food Sector
16
20
Manufacturing Sector
22
Service Sector
28
Introduction
Europe 2020 is the EUs growth strategy for the coming decade, pushing the EU to become a smart,
sustainable and inclusive economy. Under the Europe 2020 strategy the flagship initiative for a resourceefficient Europe points the way towards sustainable growth and supports a shift towards a resourceefficient, low-carbon economy. Sustainable consumption can transform environmental challenges into
economic opportunities.
Ireland has an enviable track record in sustainable consumption and resource efficiency. In 2001, the
Environmental Protection Agency (EPA) launched the Cleaner Greener Production Programme (CGPP)
as a grant scheme to encourage Irish companies and organisations to implement cleaner, greener work
practices. The CGPP is a competitive and successful programme and was highlighted as an Exemplar
Programme in a European Commission review of Eco-Innovation.
The philosophy of the CGPP is that prevention is better than cure. The programme challenges
organisations to produce goods and provide services in a more environmentally friendly way by using
cleaner production methods to prevent environmental impact rather than simply relying on end-ofpipe treatment. The objective is to achieve a balance between economic activity and environmental
protection. Approximately 100 businesses, of varied sizes across a wide range of sectors, have benefitted
from the CGPP to date. Since 2011, the CGPP has been integrated into the EPAs BeGreen initiative.
This report summarises the key findings from the CGPP over the last four years (2008-2012), presenting
case studies that reiterate the practical outcomes of each project. The report highlights the win-win
outcomes for Irish-based business and the environment, and shows that environmental improvements
can form the basis for enhanced competitiveness.
Products: reducing negative impacts along the life cycle of a product, from raw materials extraction
to its ultimate disposal.
Eco-Design: developing new products with reduced environmental impact on a life cycle basis. EcoDesign is also intended to embrace such concepts as improved recyclability, ease of repair and re-use,
and improved durability.
An important and crucial element to complement the above areas is ensuring that people are at the
core of the cleaner production and resource efficiency initiatives. New attitudes, better environmental
management and evaluating available technology options are all necessary requirements, to keep projects
on-track and achieve vital savings. Training, raising awareness and participation of staff are musts for
any project to be successful.
The philosophy behind implementing Cleaner Production is to take good environmental practice to the
stage where it is an inherent part of any business operation. Figure 1 summarises the benefits of CGPP
participation, which is demonstrated in the examples reported and the individual detailed case studies.
Environmental
Benefits
New Products
& Services
Learning and
Awareness
CGPP
Participation
Innovation
Culture
Marketing
Advantage
National &
International
Recognition
Economic
Savings
4,169
15,038,754
49,414
2,894,210
(Please note the figures are actual savings and do not reflect the estimated recoverable savings in water
of 13 million m3/annum or of CO2 savings of 40,000 tonnes per annum recorded in the FDT projects
see page 24.)
Putting some of these savings into context, we can see how these savings are more tangible on a day
to day basis.
Energy Saved:
n
Packaging Savings:
Cardboard
n
n
n
Larkins Engineering
Dawn Meats
JFC
The equivalent of 26% less plastic is used in the new fast fill water
trough for livestock, without compromising quantity or quality.
Plastic clips have been designed into the new product making it 100%
recyclable.
Micropro Computers
ChipSensors (trading
as Silicon Laboratories)
Green Isle
Redesigning the packaging for Goodfellas pizza boxes using ecodesign principles resulted in major savings cardboard savings of 460t
p.a., 100% recycled board now used; shrink wrap saving of 73t p.a.
(or 290t CO2).
Cuthberts Bakery
Two new products were developed and new markets have evolved for
these new goods.
Honeywell
Galco
Micropro Computers
International
International
Noonan
National
*Cork Institute of
Technology (CIT)
National
National
National
National
National
Larkins Engineering
Green Isle
Supermacs
BIM
SPecoServices Ltd
FDT Consulting
Cork Institute of
Technology (CIT)
Connacht Gold
Honeywell
The project itself was successful but the new concept proved
uneconomical at present to use in high volume production. The
development time required for a new product can be longer than
anticipated when development is happening in a continuous
production environment, at present.
Organic Lens
Manufacturing (OLM)/
Essidev
What did the CGPP participants think of the programme and was it all
worthwhile?
In 2010 a study was undertaken by the Centre for Innovation & Structural Change NUI Galway. This study
collected data from participants that took part in the first four phases of CGPP spanning 2001-2010.
The survey collected information on the impact of programme participation, focusing on technological
changes, economic impacts and environmental improvements as well as organisational changes in the
areas of changes to skills, knowledge and attitudes. As part of the 2010 survey data was also collected on
the longer term impact of CGPP participation, asking previous participants about ongoing achievements
in technological change, environmental awareness, as well as economic and resource savings.
69 organisations were surveyed ranging from the very early participants in 2001 up to the 2008 awardees.
Findings were impressive and overall, tells a good story of efficient & sustainable resource consumption
and usage, delivering significant environmental improvements:
The key findings & outcomes of the organisations that responded were
n
Key Outcomes:
n
Creation of new expertise and broadening of the technology base within organisations. re general
business efficiency skills that were acquired.
The full report entitled: EPA Cleaner Greener Production Programme: Experiences, Impacts and
Outcomes for Participant Organisations, Dr Rachel Hilliard, Dr Suchitra Pal and Valerie Parker Centre
for Innovation & Structural Change, NUI Galway Ireland, can be downloaded from the EPA website at:
www.epa.ie/researchandeducation/research/.
Organic Lens
Manufacturing (OLM)/
Essidev
Honeywell Turbo
Technologies Ireland
Larkin Engineering
Limited
Manufacturing
Cork Institute of
Technology
Services
Page 14
COPE Galway
Connacht Gold
Shannonside Facility
Dawn Meats
Super-Sustainable: Biodegradable/compostable
product packaging & overall improvement in
environmental performance across all Supermacs
Project LYSIS
Title
Supermacs
Water
Energy
Resource Efficiency
l
Eco-Design
l
GHG emissions
Staff Training
Economic Savings
Packaging
Table 1: Index to the case studies highlighted in their sectors, Food, Manufacturing, Information Technology and Services
Organisation
Jack Cuthberts
Handmade Bread Ltd.
Food
ChipSensors Limited
trading as Silicon
Laboratories
Information Technology
Multimedia Computer
Systems Ltd t/a MicroPro
Computers
Waste
New CP activities
Reputation/Prizes
Page 15
Food Sector
Key achievements:
n
The key element to the project is being able to measure and hence
monitor in order to in turn make savings in priority areas, such as
water leakage and energy loss. BIM will be looking to further
expand the programme in the future and sees the opportunity
for the Irish Seafood Sector to promote this programme
nationwide and to enhance the credentials of a Clean Green
and Sustainable sector.
Ballaghadereen,
Co. Roscommon, Ireland
www.connachtgold.ie
Key achievements:
n
Heavy Fuel Oil Efficiency 2010 (Litres Milk Processed per Litre of oil)
65.0
Litres processed per litre of Oil
Key achievements:
10 Actual
09 Actual
Extract fans 4%
National slicers 3%
55.0
Freezer 23%
45.0
Bread plant 7%
Soda machine 1%
35.0
Mixer 2%
25.0
15.0
8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52
Week
Key achievements:
Key achievements:
n
Awards:
The photographs below show new returnable packaging units in use the first
shows the packaging full of product and the second in its collapsed form ready for
return to Dawn Meats for refill.
Super-Sustainable at Supermacs
Key Achievements:
Key achievements:
This CGPP project has linked directly with the Groups ethos of
promoting a greener workplace with an emphasis on educating
the employees in the achievement of greener processes and
procedures.
ChipSensors Limited
(now trading as Silicon
Laboratories),
Limerick, Ireland
www.silabs.com
MicroPro Computers
Rathfarnham, Dublin, Ireland
www.iameco.ie
Awards:
This is the worlds first desktop computer to secure the EUs
coveted EcoFlower label for its exceptional standards of
environmental sustainability in manufacture and use.
At the official launch of iameco 3 Paul Maher & Jose Ospina Micropro with
Laura Burke DG EPA and President Micheal D. Higgins
Manufacturing Sector
Key achievements:
n
The main aim of the CGPP project was to carry out a process
water recycling trial, using membrane technology, with the aim
of significantly reducing water consumption. The technology
successfully recycled the process wastewater to the desired water
quality standard but due to challenges associated with recycling
efficiencies and treatment of wastewater concentrate arising
from the recycling process this strand project did not proceed
any further.
The successful outcome of this project for OLM was the installation
of an over ground rainwater harvesting system. Three 10,000 litre
tanks were installed and are now used to feed 22 toilets within
the facility. This will reduce consumption of municipal mains water
by approximately 11%, with cost savings of 4,000 per annum
Implementation of an Environmentally
Efficient Continuous Flux Treatment System
Galco Steel Ltd. is the largest hot dip galvaniser in Ireland with
plants located in Dublin, Cork, Waterford, Derry and Tynagh
(Galway). Galco Steel Ltd employs approximately 340 between
the five sites, with the principle operation in Dublin employing
175 people. Galco also produce a range of access covers and
drainage systems.
The project aim was to design and develop a new plaster mould
design for the manufacture of aluminium castings without the
use of polystyrene component in the mould.
Key achievements:
n
JFC Manufacturing,
Tuam, Co. Galway, Ireland
www.jfc.ie
Larkin Engineering,
Tuam, Co. Galway, Ireland
www.larkin-eng.com
Key achievements:
n
26% less plastic used on the new fast fill water trough while
maintaining same quantity
Awards:
Larkin Engineering received the national runner up award for the
How Green Is your Business Competition run by Dublin Chamber
of Commerce in September 2011.
Larkin also received the IBEC award for new Product Award in
2012.
Noel Larkin, MD Larkin Engineering and Bobby Kerr Dragons Den Judge.
Waste Minimisation
at Tool and Plastic Ltd.
Longford, Ireland
www.toolandplastic.ie
Key achievements:
Key achievements:
n
Service Sector
Key achievements:
n
Key achievements:
Installation of a digester
Awards:
The College Canteen became the first third-level canteen in Ireland
to receive the Green Hospitality Award and the Department of
Tourism & Hospitality received the Gold Level award.
CIT receiving one of the Green Hospitality Awards
The smart dose system that eliminates the need to gauge or guess dilutions
therefore reduces waste
Noonan, Swords,
Co. Dublin, Ireland
Key achievements:
n
Key achievements:
n
Awards:
Act
Standardise Solution
Review and Define Next Issues
Do
Devise a Solution
Develop Detailed Action
Plan and Implement It Systematically
Check
Confirm Outcomes Against Plan
Identify Deviations and Issues
R bhFREAGRACHTA
CEADN
Bonn ceadnais n-eisiint againn i gcomhair na nithe
seo a leanas chun a chinnti nach mbonn astuithe uathu
ag cur slinte an phobail n an comhshaol i mbaol:
iseanna dramhaola (m.sh., lonadh taln, loisceoir,
stisiin aistrithe dramhaola);
gnomhaochta tionsclaocha ar scla mr (m.sh.,
dantsaocht cgaisochta, dantsaocht stroighne,
stisiin chumhachta);
diantalmhaocht;
sid faoi shrian agus scaoileadh smachtaithe Orgnach
Ginathraithe (GMO);
mr-iseanna strais peitreail;
scardadh dramhuisce.
STRUCHTR NA GNOMHAIREACHTA