The sponsor has presented plans to address these impacts to ensure that the proposed project will, upon implementation of the specific measures agreed, comply with applicable host country laws and regulations and World Bank/IFC requirements. The information about how these potential impacts will be addressed by the sponsor/project is summarized in the paragraphs that follow and in the Corrective Action Plan (CAP) provided as attachment below. BrazilMarcopolo has five plants in Brazil. Ana Rech and Planalto plants located in the State of Rio Grande do Sul and Ciferal located in the State of Rio de Janeiro produce many of the needed parts for the buses bodies and assemble municipal and urban buses. MVC located in the State of Parana and Polo located within Ana Rech premises produce plastic and fiberglass components. Ana Rech. Main plant located in the city of Caxias do Sul in the State of Rio Grande do Sul is located in a combined industrial-residential area. The main activity in this plant is the assembly and finishing of municipal and urban buses. Many of the parts needed for assembly are sent to this plant from the Planalto and Polo plants, located nearby. The buses engines are provided by the bus buyers.The plant has two boilers, a 2,000 kg/hr-capacity wood burning boiler and a three million kcal/hr-capacity natural gas boiler. As part of the process, Ana Rech also has paint, arc soldering activities and dryers. As part of the CAP, Marcopolo will conduct stack and ambient air emission testing of all air emissions (i.e., boilers, paint booths, etc.) to evaluate the level of emissions being released and as needed, Marcopolo will control the air emissions to ensure compliance with the applicable World Bank guidelines.The water used is obtained from the municipal system. The operation generates industrial as well as domestic waters which are treated in a wastewater treatment plant (WWTP) prior being discharged in the nearby stream . Water used at the paint booths is reused several times before sent to the WWTP. The treated wastewater is basically in compliance with the applicable World Bank guidelines. Only coliform concentrations have to be measured and controls installed as needed to fully comply with the applicable guidelines. The WWTP sludges are disposed in Ana Rech’s secured landfill.
Ana Rech health and safety programs are OSHA 18001 certified. The plant exhibits overall good housekeeping and has developed a risk assessment program and a risk prevention program. The personnel is provided with and required to use personal protective equipment. Monitoring of work place conditions is conducted regularly. The results showed compliance with the applicable WB requirements. The paint booths are properly managed and the employees have the adequate protection systems. Ana Rech has initiated a program to address ergonomic aspects in the working areas. Details of this program will be submitted to IFC as soon as available. Ana Rech has won several recognitions for innovative projects such as reduction of energy consumption and it is currently aiming to have zero effluents discharges. This plant is working towards obtaining the ISO 14001 certification (i.e., audits are being conducted, procedures are being developed and implemented, etc.)
The plant has established an ambitious health and safety training program and has established partnership with a local government training institution (SENAI) to provide basic education to his employees and the employee children.
Marcopolo has a very comprehensive management system for the industrial solid residues generated (i.e., aluminum, paper, fiberglass, rubber, styrofoam, polyurethane, paints, solvents, rubber, etc.) It has a solid residues center at the premises with a secured landfill and a specialized manager in charge.
Planalto
Also located in Caxias do Sul, next to the Ana Rech plant, this plant produces minibuses. In addition to assembly, painting, and finishing like Ana Rech, Planalto produces many of the pieces needed for the bus bodies for both plants. The plant has a 2,000 kg/hr wood burning boiler and uses natural gas for the dryers. As part of the operation, Planalto has acid and salt baths with controlled air emission systems and well ventilated areas.
Planalto has a wastewater treatment plant to treat the industrial and domestic effluents. The chromium and cyanide effluents are treated separated before joining with the rest of the effluents to be further treated and released to the nearby stream. The treated wastewater is basically in compliance with the applicable World Bank guidelines. Minor adjustments are required to be made to ensure that suspended solids and chemical oxygen demand concentrations are in compliance. In addition, Planalto will measure coliform concentrations and as needed enhance the current treatment to ensure compliance with the applicable guidelines. The sludges are disposed in Marcopolo’s secured landfill.
The plant exhibits overall good housekeeping and has developed a risk assessment program and a risk prevention program.. The personnel is provided with and required to use personal protective equipment. Measures to reduce employee exposure to high noise have been implemented. The paint booths are properly managed and the employees have the adequate protection system s. Monitoring of work place conditions is conducted regularly. The results showed compliance with the applicable WB requirements. and Health and Safety programs are OSHA 18001 certified.
The hazardous materials (i.e., nitric acid, sodium and fluor cyanide, etc.) are properly handled. They are stored in an enclosed area with double containment and distant from the operations.
Ana Rech and Planalto has responsible personnel to handle the environmental and health and safety aspects of their operations.
Polo
Located within the premises of the Ana Rech plant, manufactures both ABS and fiberglass parts required for the assembling of the buses bodies at the Ana Rech and Planalto plants. The vapors generated in the working areas as part of the operations ought to be controlled. As part of the CAP, Polo will improve the ambient air conditions in the working areas to ensure that the employee exposure complies with the applicable requirements. The domestic and industrial wastewater generated are sent to and treated in the Ana Rech WWTP.
The residues are properly collected and segregated. The storage area where the wastes are maintained prior to final disposal will need to be improved to prevent soil and or groundwater contamination. All wastes are segregated and properly disposed. Many of the wastes are recycled or sold for reuse. In addition, Polo is developing innovative uses for these residues such as using plastic residues mixed with concrete for the production of bricks which have already been used in their own premises.
The plant exhibits overall good housekeeping. As part of the project, Marcopolo will improve further the health and safety programs at Polo.
The operations in Caxias do Sul are required to develop and implement contingency and emergency response plans as established in the CAP. Copies of these plans will be submitted to IFC satisfaction as per the CAP in Table 1.
Plantation
The wood for Ana Rech and Planalto are obtained form their own eucalyptus plantations located at approximately 17 km from the industrial site. The plantation has approximately 49 hectares of which 30 ha are planted. The remaining area is maintained as preservation area. The plantation is licensed by the local authorities to operate. The day-to-day activities are sub-contracted.
Ciferal
Located in the city of Duque de Caxias in the State of Rio de Janeiro and like the Caxias do Sul plants this one also assembles municipal and urban buses. It uses natural gas as fuel and treats its water prior being used in their premises. The treated water is also used to provide drinking water to the suburb of Xerem (city of Duque de Caxias).
This plant has a dry painting process avoiding thereby the generation of industrial wastewater. The domestic wastewater generated are released into the municipal system. Ciferal is committed to build, as required, a wastewater treatment when its operations generate wastewater.
The solid residues generated are collected and handled by a government licensed company . The plant exhibits overall good housekeeping. The employees are provided with and require to use personal protective equipment. Workplace monitoring is conducted periodically and follow-up of causes and prevention of accidents/incidents is also implemented. The plant has personnel responsible for health and safety operations.
MVC
Located in Sao Jose dos Pinhais in the State of Parana produces high technology plastic components by using technologies such as, resin transfer forming (RTM), vacuum forming, extrusion, and fiber printing for Marcopolo operations as well as other sectors (i.e., railroad, telecommunication, visual arts.) Seventy percent of its production is plastic and the remaining thirty percent is fiberglass Sixty percent of the raw material used is recycled material. MVC is motivating the recycling culture in their area and the use of products made with plastic which can be reused as opposed to fiberglass which has a extremely long biodegradation time.
LPG is the fuel used for the dryers. The rest of the operation uses power from the electrical grid. The water used is obtained from the municipal system. Currently, the wastewater generated are collected in barrels and send for final disposal through an authorized company. As part of the CAP, MVC will build a wastewater treatment plant. This plant anticipates it will obtain ISO 14001 certification by 2004.
MVC has personnel responsible for the health and safety programs. The employees are provided with and required to use the acetone that is recycled and reused in the process. MVC has developed a risk assessment program and a risk prevention program. The corresponding mitigation actions are being developed. This plant is also developing an ergonomics program.
As part of the project, MVC will open an additional plant in Caxias do Sul. This plant will be designed to operate in full compliance with the applicable World Bank guidelines. Details of this plant will be submitted to IFC as a condition of the first disbursement.
Mexico
Polomex
This plant, located in Monterrey, Mexico also assembles municipal buses. This operation is a joint venture between Mercedes Benz and Marcopolo. Polomex installations are located in the Mercedes Benz plant premises.
The plant uses natural gas as fuel. Like the operations in Brazil, Polomex also includes paint and arc soldering operations. The paint booth has dry filters, and the operators used full filter masks and closed overall clothing.
Particulate ambient air emissions, wastewater concentrations, workplace parameters (i.e., noise, vapors, VOCs, etc.) are being conducted. Polomex will submit the results to IFC as well as the measures to be implemented, if needed, to ensure that their operations comply with the applicable World Bank guidelines. The corrective actions as well as associated costs and implementation schedules will be presented to IFC as per the CAP in Table 1.
Other Locations
Marcopolo has also bus body production in Colombia, South Africa and Portugal. With an environmental corporate structure, Marcopolo can ensure that all its operations will operate under sound environmental and health and safety practices.
Even though, Marcopolo operations, independently, have overall good environmental, health, and safety practices, Marcopolo does not have an environmental corporate policy nor a structure that allows for consistency, exchange, and benchmarking of good practices. Thus, as part of the CAP, Marcopolo will develop a corporate environmental policy and implement a corporate environmental management system.
