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 countries laws and regulations and the World Bank/IFC environment and social performance standards 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. Further information is provided in the attached ESAP, which is agreed upon by IFC and CAME and will address the compliance gaps with IFC’s requirements.
- Social and Environmental Assessment and Management Systems:
Land and natural environment: All CAME operations are located in sites approved for industrial operations. The site of the Cali paper Mill has been surrounded by commercial and residential sectors as the original Industrial sector was converted to a Mixed land use sector. The site of the Chile corrugating plant is surrounded by agricultural and recreational home areas.- Neither plant is located near sensitive locations or cultural properties. As part of the project with IFC, 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 in accordance with IFC performance standards on involuntary resettlement.
Environmental and Social Assessment. CAME has a corporate Environmental, Health and Safety structure reporting directly to Senior Management and each of the plants has dedicated personnel to handle these aspects. In addition, as needed CAME hires external experts to conduct monitoring, audits, and environmental impact assessments (EIA) as needed. CAME also has developed performance targets and indicators (i.e., m3 water/ton paper produced, wastewater pollutant load/ton paper produced, waste generated, starch and ink consumption, etc.) to track and benchmark the performance of its operations. All plants continue to develop programs aimed to reach those levels and, whenever possible, with the aim of reaching zero-industrial discharge operations. Energy, water, and fuel statistics for all plants from the previous years show a consistent pattern of lowering consumption at all plants.
EHS management and organization. CAME has a fully established EHS management system. All plants in Colombia, Ecuador, Peru and Venezuela are certified ISO 9001-2000, and the plants of Colombia received in 2.006 the OHSAS 18001 certification. CAME is extending same health and safety practices acquired in the Colombian sites to the rest of its operations to further enhance current H&S at all sites outside Colombia.
Training, monitoring, and reporting. CAME programs in place to provide the necessary EHS training for all its employees, including the initial orientation and annul refresher training. CAME conducts routine EHS monitoring for its operations and requires the contractors to meet all its EHS requirements. It provides as needed appropriate training for the contractors. CAME conduct periodic EHS monitoring of its operations. In addition, the local environmental authorities also conduct audits to ascertain compliance of CAME operations with the local requirements. CAME keeps the EHS performance records of all its operations through its internal reporting structure and submits environmental reports to the local authorities of all countries were it operates.
- Labor and Working Conditions:
Human Resources Policy and Management: The Company has a Human Resources policy which specifies the terms of employment and working conditions at CAME. These include procedures for hiring, probation, training, performance review, promotion, insurance, salary and compensation, resignation, lay-off and firing, leave and vacation, and retiring, which follow the labor laws of all countries were it operates. All the employees have access to the human resources policy and procedures. The Governments sporadically conduct labor inspections to ascertain compliance with local laws.
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 75% of the employees in Colombia take part in the Employee Fund.
Workers Organizations:
CAME and its subsidiaries employ a total of 731 workers. There are labor unions in the Venezuela and Chilean operations, and labor collective agreements in Colombia. CAME allows collectively bargaining for both employees and contracted labors. The company management has formal mechanisms to handle and resolve complaints by the employees and contracted laborers.
Non-Discrimination and Equal Opportunity: CAME provide equal opportunities for its employees. All the hiring and promotion are merit-based.
Retrenchment: It is not anticipated that there will be any significant retrenchment. As a result of IFC’s financing or the expansion, more direct jobs will be created in Venezuela, and more indirect jobs will be created in the recycling sector in Colombia, Peru and Venezuela.
Protecting the Workforce: There is no child or forced labor in CAME. The company also ensures that the contracted laborers are at least 18 years old.
Occupational health and safety:
The company has its corporate occupational health and safety (OHS) department and each plant in turn, has personnel responsible to handle the respective OHS aspects. There are effective OHS procedures such as safe operational procedures and personal protection equipment requirements for each position, which are implemented during operations. The plants have 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. There are routine OHS training session including annual refresher courses for its employees and contracted laborers. As indicated in the ESAP, CAME will further develop systems and procedures at corporate and at plant level, to further enhance the health and safety conditions of its employees.
Monitoring of work place conditions is conducted regularly. The monitoring results showed compliance with the applicable World Bank (WB) requirements. The drinking water onsite meets both local regulatory requirements and WHO guideline limits.
Pollution Prevention and Abatement:
Raw materials and resource consumption. Main raw materials used include recycled paper and water and the fuel source for the boilers is mainly natural gas. CAME has programs to ensure all its plants are energy efficient, have optimum water use and reduction of pollutants at the source. CAME also has developed performance targets and indicators (i.e., m3 water/ton paper produced, wastewater pollutant load/ton paper produced, waste generated, starch and ink consumption, etc.) In addition, all process wastewater discharges are being systematically reduced through process procedures, thus aiming wherever possible to obtain zero discharges. These reduction targets are monitored closely by management.
A significant part of the water source of the Corrugator Plant (CORAME) in Bogota, Colombia is the rain water which is collected and used in the process.
Air Emissions, Liquid Effluents, and Ambient Conditions. Since natural gas is the fuel used at all plants where this fuel is available, (natural gas is not yet available at the paper Mill in Chincha, Perú and the Chilempack corrugating plant), and there are optimum combustion practices in place, CAME’s air emissions are within local and IFC requirements. Most of the corrugating plants are reaching zero industrial effluent discharges. As indicated in the ESAP, CAME will submit to IFC a program to ensure all its discharges fully comply with the applicable IFC requirements. Since there are not significant releases to the atmosphere, and the noise levels are kept below requirements CAME plants do not affect negatively the ambient conditions.
COLOMBIA - Cali - Paper Mill. Its fire-tube boilers use natural gas and low sulfur oil as back-up. The infra-red drier uses natural gas and propane, and the hot air tunnel use natural gas and alternatively diesel No. 2. The plant has an optimum combustion program thus properly controlling air emissions.- Boiler #5 also has two dry cyclones to reduce to a minimum the emissions to the atmosphere, in the eventual use of back-up fuel oil. The gases generated at the biodigestor during the anaerobic stage of the wastewater treatment plant (WWTP) are being collected and used to produce steam in a 40 BHP boiler. The biodigestor also has a flare which is used only when the steam boiler is occasionally down for maintenance. All air emissions comply with the applicable WB guidelines.
The industrial effluent is treated in an anaerobic digester.- These treated effluents are further treated in an additional aerobic system with the aim that the COD, BOD, and SS are in compliance with the applicable World Bank guidelines. The domestic waters are treated in septic tanks.
COLOMBIA - Cali - Corrugator Plant (Litofan). The two fire tube boilers use 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 is treated in a waste water treatment plant (WWTP) consisting of a coagulant mixing tank, a sedimentator, with sand bed to dry the sediment, and the treated water is stored for reuse in the ink plate washing system.- 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 plate engraving section. CAME continues with its plans to study and test environmentally friendly solvents and other technologies to replace the perchloroethylene.
COLOMBIA - Bogotá - Corrugator Plant (CORAME). This plant has two fire tube boilers, one recently installed which uses natural gas, and another one that will be only used as back-up in the very infrequent events of natural gas interruptions, using fuel oil.- This second boiler 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. Process wastewaters are used primarily for the production of starch. CORAME has installed an efficient system to treat their effluents, which are recirculated back into the process (i.e., plates washing) thus having a zero-effluents operation. As indicated in the ESAP, the chemical dosification at the WWTP will be upgraded to prevent the employees to chemicals exposure. The domestic waters are released to the city sewer after they are passed through a grease trap.
CHILE - Santiago de Chile – Chilempack – Corrugator Plant.- This plant has one fire tube boiler using fuel oil. Its particle emission is fully controlled, with a system of lime and bag filters . The particulate emissions meet the very stringent requirements of the Santiago Region. A new boiler with better heat transfer efficiencies will be installed.- This plant has also installed a system to ensure there are not effluents discharged. All treated effluents are currently fully recycled back into the process.
ECUADOR - Quito - Corrugadora Nacional S. A. CRANSA - Corrugator Plant. There are two fire-tube boilers, using No. 6 fuel oil, and which can 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. Process wastewaters are used primarily for the production of starch. The relatively low flow generated goes to a waste water treatment plant (WWTP), consisting of mixing with coagulant and a sedimentation stage prior to discharge into the municipal system. The domestic waters are released to the city sewer after they are passed through a grease trap.
PERU – Lurin - Papelera del Sur – Corrugator Plant. It now has one boiler operating on natural gas, and a second back-up boiler to be used with No. 6 fuel-oil in the very infrequent events of natural gas interruptions.- This last boiler 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 two wells belonging to the industrial park, and water for the boiler water is brought by truck. This plant, following CAME’s corporate policy, has also significantly reduced the production of wastewaters through overall process optimization. The majority of its treated process wastewaters is used in the production of starch and the remaining minimal flow generated will 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.
PERU - Chincha - Papelera del Sur – Paper Mill. There are two fire-tube boilers using No. 6 fuel oil. 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 two wells. Approximately sixty percent of its effluent is recirculated back into the process; the remaining forty percent after being treated in a primary sedimentation stage is released to be used in irrigation by a nearby farming community, ensuring compliance with the local requirements as well as the WB guidelines.. The domestic waters are currently treated in septic tanks.
VENEZUELA - Valencia - Venezolana de Cartones Corrugados - Corrugator Plant. There is a natural gas boiler. Air emissions comply with the applicable local and WB guidelines. Work is under way to reuse un-treated wastewaters for starch preparation and of treated waste water for ink plate washing. Meters have also been installed on the different printers, general incoming line, and boiler-make up water, to control usage. Process water is obtained from local utility company and industrial center well. Drinking water is purchased in bottles.
- Solid and hazardous wastes:
COLOMBIA - Cali Paper Mill. A significant part of the solid wastes generated at this plant are sold or donated for reuse. The sludge from the biodigestor is dried and use in agriculture. Granular sludge has been sold for other biodigestor start-ups.- The methane gas, generated at the digester, as by-product, is used to generate steam, and the wastes from the tailing screen and from the last stage cleaners are being used to produce a fertilizer. As part of CAME’s continuous interest to reuse the industrial residues, the Company is sponsoring an initiative to manufacture briquettes with the sand-residue from its operations. The remaining solid waste is disposed in an authorized municipal landfill.
COLOMBIA - Cali - Corrugator Plant (Litofan). Most solid waste is recycled and sent to the paper mill for reuse. The remaining is disposed in an authorized municipal landfill. Currently it is considering initiatives to optimize the process so that the amount of wastes generated is further reduced. Sludge from the WWTP is sent for incineration.
COLOMBIA - Bogotá - Corrugator Plant (CORAME). The majority of the industrial residues generated are reused. The remaining is disposed in an authorized 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.
CHILE - Santiago de Chile – Chilempack. The majority of the industrial residues generated are sold to paper mills for reuse. The remaining is disposed in an authorized municipal landfill. Currently there are initiatives to optimize the process so that the amount of wastes generated is reduced.
ECUADOR - Quito - Corrugadora Nacional S. A. CRANSA - Corrugator Plant. The majority of the industrial residues generated are sold to paper mills for reuse. The remaining is disposed in an authorized municipal landfill. Currently, the WWTP sludge are disposed in a sanitary landfill and will be incinerated as this service becomes available.
PERU –Lurin - Papelera del Sur – Corrugator Plant. 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 remaining is disposed in an authorized municipal landfill.
PERU -Chincha - Papelera del Sur – Paper Mill. The solid waste generated is sent to an approved landfill.
VENEZUELA - Valencia - Venezolana de Cartones Corrugados - Corrugator Plant. Environmentally friendly inks are also used. Main solid waste is recycled to be used in paper mills. The remaining is disposed in an authorized municipal landfill
Hazardous materials and operation hazard. Hazardous materials used at the paper mills include alum, caustic soda, chlorhydric acid, etc. CAME has established procedures, at all mills, 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. At the corrugators, CAME also has programs in place to ensure all materials are handled and stored properly.
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.
Fire prevention and emergency response. All plants exhibit very good housekeeping, are clean, well signaled and overall have adequate fire fighting systems and equipment. CAME has a management program and procedures for fire prevention and emergency response (ER). Fire prevention and ER are included in new employee/contractor training and annual refreshers. At all plants, there are systems in place to ensure both routine first aid response and emergency care. Even though CAME conducts routine drills for fire fighting; it will further enhance and develop a systematic program for all plants and will also upgrade the emergency response plans at all its plants as indicated in the ESAP.
COLOMBIA - Cali Paper Mill. The plant has safety measures in place including eye washing stations near chemical usage points and has developed risk prevention programs. 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, with the support of a part time medical doctor, a part time nurse, and the person in charge of safety and health programs.- Annual medical tests are conducted for all employees.
COLOMBIA - Cali - Corrugator Plant (Litofan). 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. The plant also has a safety committee made up of workers and managers, with the support of a part time medical doctor, part time nurse, and the person in charge of safety and health programs. Annual medical tests are conducted for all employees.
COLOMBIA - Bogotá - Corrugator Plant (CORAME). Environmentally friendly inks are also used at this plant. 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, with the support of a part time medical doctor, and the person in charge of safety and health programs. Annual medical tests are conducted for all employees.
CHILE - Santiago de Chile – Chilempack. 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, with the support of the person in charge of safety and health programs.
ECUADOR - Quito - Corrugadora Nacional S. A. CRANSA - Corrugator Plant. Environmentally friendly inks are used.
The plant has fire prevention/response equipment in place. As part of the preparation, training programs in fire prevention including trained fire brigades, equipment, etc. are developed. The plant also has a safety committee made up of workers and managers, with the support of the person in charge of safety and health programs.
PERU – Lurin - Papelera del Sur – Corrugator Plant. The plant uses environmentally friendly inks (i.e., without heavy metals). Perchloroethylene is the solvent current used in the printing plate engraving section and it is recycled. CAME is already studying and testing environmentally friendly solvents and other technologies to replace perchloroethylene. This plant has developed a risk assessment plan. 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. CAME conducted a safety audit in this plan and has identified all areas in need of improvement. Safety instructions for prevention/protection are being developed. Fire prevention measures are in place at the plant and it is developing a training program.
VENEZUELA - Valencia - Venezolana de Cartones Corrugados - Corrugator Plant. 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 part time medical doctor and nurse, and the person in charge of safety and health programs
Green House Gases (GHGs) . The main effort from CAME to lower GHG’s has been in the switch from No. 6 fuel oil based fuels to natural gas, the energy savings associated with the cogeneration project at the Cali Paper Mill, and the use of the methane from the biodigestor to produce steam in a fire tube boiler, which was locally adapted to the burning of the biogas.- Even though CAME’s GHGs are not significant, the company will begin calculating its GHGs levels and continue supporting initiatives to reduce green house gases. Details will be submitted to IFC as per the ESAP.
- Community Health, Safety and Security:
CAME has programs in place to reduce negative risks to the nearby communities. Only two plants have close proximity of residential areas, Cali Paper Mill and Chilempack, even though both are located in areas which are approved for industrial use. Chilempack is in a rural area surrounded by agricultural fields and some cottages used mostly during weekend and vacation periods.
COLOMBIA - Cali Paper Mill. 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 address any complaint by the community. (In the last two years, it has only received complaint that arose from the noise produced by a safety valve that operated during the start-up of the cogeneration plant while the system was adjusted. Additional to correcting the operation parameters to avoid the safety valve opening, silencers were added to the discharge of the safety valves, and the community was invited to visit and informed of each step of the corrective measures.)
COLOMBIA - Bogotá - Corrugator Plant (CORAME). 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. In addition, community risks related to transportation have significantly reduced.
For Chilempack, CAME will develop a Safety Transportation Plan as indicated in the ESAP.
