The sponsor has presented plans to address these impacts to ensure that the proposed project will upon implementation of the specific agreed measures, comply with the environmental and social requirements - the host country laws and regulations and the World Bank/IFC environment and social policies and the environmental, health and safety guidelines. The information about how these potential impacts will be addressed by the sponsor/project is summarized in the paragraphs that follow.
COLOMBIA
Cali Paper Mill
There are 5 fire-tube boilers using natural gas and low sulfur oil as back-up. The drier uses natural gas and propane, and the hot air tunnel uses natural gas and alternatively diesel No. 2. In addition the biodigestor from the wastewater treatment plant (WWTP) has a flare. The plant has a rigorous combustion control program and one of the boiler that uses fuel oil has two dry cyclones to ensure the emissions to the atmosphere are minimum. Air emissions comply with the applicable WB guidelines.
Process wastewater discharges are being systematically reduced through process procedures. The industrial effluent is treated in an anaerobic digester, degasified, and oxygenized before being discharged to the municipal system, thus reducing significantly the odor concentrations. These treated effluents will be further treated in an additional aerobic system to ensure that the COD, BOD, and SS are in compliance with the applicable World Bank guidelines. This system will be installed by December 2004. The domestic waters are treated in septic tanks.
Most of the solid wastes generated at this plant are sold for reuse. The sludge from the biodigestor is dried and use in agriculture. The methane gas, generated at the digester, as by-product, is intended to be used in the process. As part of CAME’s continuous interest to reuse the industrial residues, it is sponsoring an initiative to manufacture briquettes with the sand-residue from its operations, as well as a research to produce fertilizer with a tailing screen waste.
Hazardous materials used include alum, caustic soda, chlorhydric acid, etc. CAME has established procedures to store and handle these materials in a safe manner. They are stored in enclosed areas with double containment and distant from the operations. There are also safety instructions for handling these materials and personnel are trained about prevention/protection measures.
The plant exhibits very good housekeeping, it is clean, well signaled, it has eye washing stations near chemical usage points and has developed risk prevention programs. The plant has health and safety programs aimed at minimizing workplace accidents/incidents. Personal protection equipment is provided and required to be used by the employees, as needed. Monitoring of work place conditions is conducted regularly. The monitoring results showed compliance with the applicable WB requirements.
The plant has in place fire prevention measures including trained fire brigades available at all times, performance of fire drills, and installation of fire prevention/response equipment such as extinguishers throughout the plant for the various fire precursors, and hydrants. In addition, the plant also has a safety committee made up of workers and managers, a medical doctor, and the person in charge of safety and health programs.
Since the paper mill is surrounded by residential areas, CAME takes part of a mutual help committee with the neighboring community, and participates in the “Good Neighbor” campaign.- It has also established an open door policy to any complaint by the community, and has taken action in response to the few complaints they report receiving (noise and odor control).-
COLOMBIA
Cali - Corrugator Plant (Litofan)
There are two fire tube boilers using natural gas and fuel oil as back-up. Air emissions comply with the applicable WB guidelines. Process wastewaters are used in its majority for the production of starch. The minimum flow generated goes to a sedimentation tank prior discharging into the municipal system as agreed with the municipal authorities. The domestic waters are released to the city sewer after they are passed through a grease trap.
The plant uses environmentally friendly inks (i.e., without heavy metals). Perchloroethylene is the solvent currently used in the printing section. However, CAME is already testing environmentally friendly solvents to replace the perchloroethylene. As soon as they identify the solvent that has both good technical performance in addition to being recoverable, CAME will begin using the new solvent in all its printing operations. Most solid waste is recycled and send to the paper mill for reuse. Currently there are initiatives to optimize the process so that the amount of wastes generated is reduced.
This plant also exhibits very good housekeeping, it is clean, and is well signaled. The plant has health and safety programs aiming to minimize workplace accidents/incidents. Personal protection equipment is provided and required to be used by the employees, as needed. The plant also has fire prevention measures in place and has a safety committee made up of workers and managers, a medical doctor, and the person in charge of safety and health programs.
In Cali, CAME is part of a voluntary association called Responsible Care, which addresses aspects such preparation of the community for emergencies, safety in distribution and transport, safety in processes, environmental protection, and safety and health of the workers.
CAME will continue its participation supporting a medical care and attention to single mothers and kids program in the area of Aguablanca in Cali. This program takes place in a very low income community with approximately 300 000 kids younger than 18 years old. CAME’s participation has been increasing yearly and will continue to do so.
COLOMBIA
Bogotá - Corrugator Plant (CORAME)
This plant is located at 20 km from Bogotá, Colombia. There is a fuel-oil boiler which operates under a rigorous combustion control program to ensure its emissions are minimal. The emission tests conducted indicate that the emissions comply with the IFC guidelines.
The main water source are the rain waters which are collected and use in the process. Process wastewaters are used primarily for the production of starch. The relatively small flow generated goes to a sedimentation tank prior discharge into the municipal system. Currently, CORAME is testing a biological system to treat their effluents with the aim to recuperate its wastewaters, recirculate them into the process (i.e., plates washing), and have a zero-effluents operation. As soon as this treatment proves effective, CAME will adopt this approach in all its corrugator plants. The domestic waters are released to the city sewer after they are passed through a grease trap.
The majority of the industrial residues generated are reused. The remaining are disposed in the municipal landfill. Currently there are initiatives to optimize the process so that the amount of wastes generated is reduced. Sludge from the WWTP is sent for incineration.
Environmentally friendly inks are also used at this plant.
The plant has health and safety programs to minimize workplace accidents/incidents. Personal protection equipment is provided and required to be used by the employees, as needed. The plant has fire prevention measures in place, including trained fire brigades available at all times, performs fire drills, and fire prevention/response equipment such as extinguishers throughout the plant for the various fire precursors, and hydrants are installed. This plant also has a safety committee made up of workers and managers, a medical doctor, and the person in charge of safety and health programs.
The transportation of raw materials and products in this plant as well as in the other CAME operations is subcontracted. CORAME took the proactive initiative of training and supporting its local transport subcontractors so that they formed their own cooperative. This new organizational structure has proven very effective for the plant as well as the contractors, the overall safety, performance, and operational standards have been significantly upgraded.
VENEZUELA
Valencia - Venezolana de Cartones Corrugados - Corrugator Plant
There is a natural gas boiler. Air emissions comply with the applicable WB guidelines.
Domestic and process wastewaters go to a WWTP (physical, chemical, biofilter) prior discharging into an open wastewater collector. As part of its improvements, VCC will segregate the domestic and the industrial waters, treat the industrial waters so they can be reused into the process (i.e., plates washing, starch preparation, etc.) and treat the domestic waters to acceptable WB levels prior being discharged. This system will be installed by December 2004.
Environmentally friendly inks are used (without heavy metals). Main solid waste is recycled to be used in paper mill. Currently there are initiatives to optimize the process (i.e., widening of corrugators) so that the percentage amount of wastes generated is reduced.
The plant has health and safety programs to minimize workplace accidents/incidents. Personnel protection equipment is provided and required to be used by the employees, as needed. The plant has fire prevention measures in place, including trained fire brigades, performance of fire drills, and fire prevention/response equipment installed. The plant also has a safety committee made up of workers and managers, a medical doctor, and the person in charge of safety and health programs.
ECUADOR
Quito - Corrugadora Nacional S. A. CRANSA - Corrugator Plant
There is a fuel-oil boiler, which also uses diesel oil. CRANSA has a rigorous combustion control program to ensure the emissions are minimal. Air emissions comply with the applicable WB guidelines. This plant has a program of water use optimization and of reduction of pollutants at the source, which demonstrates an effective use of resources and equipment.
Process wastewaters are used primarily for the production of starch. The relatively low flow generated goes to a sedimentation tank prior to discharge into the municipal system. The domestic waters are released to the city sewer after they are passed through a grease trap.
Environmentally friendly inks are used (i.e. without heavy metals). Currently, the WWTP sludges are disposed in a sanitary landfill. However, CRANSA is currently assessing alternatives for the reuse of these residues. Unlike before, these residues do not contain heavy metals and can be reused. As soon as CRANSA has identified the most adequate alternative to the landfill, it will inform IFC.
The plant has health and safety programs aiming to reduce to the minimum workplace accidents/incidents. Personal protection equipment is provided and required to be used by the employees, as needed. The plant will have in place its fire prevention/response equipment by March 2004. As part of the preparation, training programs in fire prevention including trained fire brigades, equipment, etc. are being evaluated. The plant also has a safety committee made up of workers and managers, a medical doctor, and the person in charge of safety and health programs.
As part of its restructuring program, CRANSA had a retrenchment program through which it reduced the plant’s workforce by approximately 20 percent (24 employees). CRANSA indemnified these twenty four people in accordance with Ecuadorian regulations. In addition, approximately half of these people are currently providing services to CRANSA as sub-contractors (e.g. commercial agents, transport, gardening, electrician, etc.)
PERU –
Lurin - Papelera del Sur – Corrugator Plant
This plant is located at 30 km from Lima. It has a No. 6 fuel-oil boiler with a rigorous combustion control program to ensure the emissions are minimal. Air emissions comply with the applicable WB guidelines.
Process water is obtained from two wells and water for the boiler water is brought by truck. As part of the project, CAME will treat and use underground water in the boiler as well. Thus, it will build a water treatment system an install a water storage tank.
This plant, following CAME’s corporate policy, has also significantly reduced the production of wastewaters through overall process optimization. The majority of its process wastewaters will continue to be used in the production of starch and the remaining minimal flow generated will continue going to a sedimentation tank prior to discharge into the municipal system. It is currently working an initiative to treat its wastewater and used it for irrigation purposes, to achieve a zero effluents operation. The domestic waters are released to the city sewer after they are passed through a grease trap.
The plant uses environmentally friendly inks (i.e., without heavy metals). Perchloroethylene is the solvent current used in the printing section and it is recycled. CAME is already testing environmentally friendly solvents to replace perchloroethylene. As soon as a solvent with good technical performance characteristics as well as one that is recoverable is identified, CAME will begin using the new solvent in all its printing operations.
Most solid waste is recycled to the paper mill. Currently there are initiatives to optimize the process so that the amount of wastes generated is reduced.
The plant has health and safety programs aimed at minimizing workplace accidents/incidents. This plant is currently developing a risk assessment plan. Personal protection equipment is provided and required to be used by the employees, as needed. The plant has fire prevention measures in place, including trained fire brigades, performance of fire drills, and installation of fire prevention/response equipment. A medical doctor and ambulance are available to all of the enterprises located in the industrial park where this plant is located.
PERU
Chincha - Papelera del Sur – Paper Mill
There is a No. 6 fuel-oil boiler. The plant has a rigorous combustion control program to ensure the emissions are minimal. Air emissions comply with the applicable WB guidelines.
Process water is obtained from one well. Currently, the liquid effluents go through a filter and are released without treatment. The local authorities have requested that pre-treatment be conducted before the wastewaters are released into the municipal system for further treatment. Currently, lead levels in the wastewaters are above World Bank guidelines. CAME will install the needed treatment system to ensure compliance with the local requirements as well as the WB guidelines. This system will be in operation by the end of 2004. In addition, as with the rest of CAME, this plant is going through a rigorous program to reuse its process waters and thus treat and discharge just minimal wastewater amounts. It is anticipated that treated wastewater will be used for irrigation. This program will be fully implemented by the end of 2006. The domestic waters are currently treated in septic tanks. New septic tanks will be operational by the end of 2003.
CAME conducted a safety audit in this plan and has identified all areas in need of improvement. It is anticipated this plant will have the same safety levels are the rest of CAME plants. The specific safety program will be submitted to IFC before the first disbursement. Personal protection equipment is provided and required to be used by the employees, as needed. Fire prevention measures are in place at the plant and it is developing a training program. The plant is also developing safety instructions for prevention/protection. A medical doctor is available. He conducts annual tests for all employees.
The solid waste generated is sent to an approved landfill. Hazardous materials used include alum, caustic soda, chlorhydric acid, etc. CAME has established procedures to store and handle these materials in a safe manner. They are stored in an enclosed area with double containment and distant from the operations.
As part of its restructuring program, Papelera del Sur had a retrenchment program by which it reduced its workforce by approximately 30 percent (60 employees). CAME indemnified these sixty people in accordance with Peruvian regulations. Approximately half of these people were able to find employment in the provision of services to Papelera del Sur as sub-contractors (i.e. commercial agents; transport; gardener; recycled paper collectors; and security guards, which were hired by the companies used by CAME.)
Corporate Initiatives
CAME has a corporate environmental policy and a team assigned to handled corporate environmental, health and safety and human resource aspects. In addition, it has delegated environmental and health and safety responsibility to each plant manager. CAME also has developed performance targets and indicators (i.e., m3 water/ton paper produced, wastewater pollutant load/ton paper produced, waste generated, ink consumption, etc.) All plants continue to develop programs aimed to reach those levels and to reach zero-discharge operations. Energy, water, and fuel statistics for all plants from the previous years show a pattern of consistently lower consumption at all plants.
Since life and fire safety are among the main concerns of all personnel at all levels, CAME encourages its employees to identify potential risks and measures to prevent fatalities and fires.
CAME has developed an Emergency Response Program that needs yet to be implemented. Personnel from all its operations will be fully trained by the end of 2003.
For all plants, independent laboratories measure the emissions to the environment periodically. HCFCs are the coolants currently used at all plants. However, all new equipment to be installed will have non-ozone depleting substances as they become commercially available from the equipment manufacturers.
As part of the project, the CAME is committed to abstaining from implementing expansions or improvements that will result in the resettlement of individuals or business until CAME has submitted to the IFC, and the IFC has approved, a specific Resettlement Action Plan to deal with such situation in compliance with IFC policies on involuntary resettlement.
In Bogotá, CAME is part of a new program where the municipality will build several recycled waste centers, and contract the operation of these plants to organizations with participation of the street collectors. CAME, together with some of its suppliers (recycled paper companies and street collectors in and around Bogotá), has taken part in a non-governmental Foundation, which is applying to operate one of these new recycling centers.
CAME has actively supported its workers in the purchase of homes and in Cali about 90% of the workers are homeowners. This same plan is being implemented in CAME’s newer acquisitions (i.e. Peru and Ecuador). Also CAME encourages savings and has a plan where it donates 30% of the amounts saved to an employee savings fund, and 73% of the employees in Colombia take part in the Employee Fund.
CAME has encouraged the formation of small and medium enterprises, in several services areas, such as personnel transport, maintenance services, transport company for finished products in Bogotá, corrugator carton dividers production and pre-assembly plants in Cali and Bogotá.
