Environmental and Social Assessment and Management System - In alignment with good industry practices, the client has developed and implemented an integrated management system to manage the environmental, social, health and safety (ESHS) risks associated with its operations. Molca is the largest producer of wheat flour in Argentina, processing 28.5% of the wheat in Argentina in 2016. Operations include 21 production facilities located in Argentina, Uruguay, and Brazil., including the new Spegazzini Plant, which started operations in the first semester of 2015. Origination activities include 19 facilities across the country. Apart from Spegazzini, the facilities hold certifications for ISO 9001, ISO 14001, OHSAS 18001 and ISO 22000. At present, the Cañuelas Plant also has the GMP+ Certification. At the Corporate level, the client has implemented ISO 27001 and is in the process of seeking certification for ISO 50001.
In 2015, Molca began carrying out internal and external audits to test and verify its systems compliance with IFC requirements. The client has a robust program for assessing and managing ESHS risks, which includes frequent inspections, internal audits, external audits, certification audits and inter-plant audits and reviews by upper management. Along with the various certifications it has obtained over the past couple of years, the client has developed an action plan to implement corrective actions identified by the various internal and independent auditors. To strengthen and improve implementation of the new ESMS, Molca will scale up the size of its teams across all industrial plants and facilities as necessary, whilst ensuring continued training and cross-coordination with relevant departments. An action plan detailing the objectives, timeframes and details, such as budget, qualifications, training, roles and responsibilities, of the proposed expansion leading up to 2016 were submitted to IFC and deemed appropriate and sufficient to ensure continued and consistent good performance from the client in respect to day to day compliance with environmental, health and safety, and quality (EHSQ) responsibilities.
EHS risks of manufacturing activities include workers’ exposure to noise, vibration and particulate matter, physical hazards (electrical hazards, confined spaces, slippery surfaces, particulate matter, risk of fire and explosion, collision with moving equipment, ergonomic, exposure to chemical hazards, etc.), generation of Greenhouse Gas emissions, high energy and water consumption, generation of solid waste and liquid effluents, among others. Risks associated with origination activities involve supply chain issues and worker occupational health and safety. A similar assessment of environmental risks and impacts exists for all origination activities, and an action plan is currently being implemented for each facility, audited annually.
To ensure compliance with statutory requirements, the client relies on the services of a consulting firm who stays abreast of all regulations that apply to the operations at each facility, and ensures that the Company remains compliant with applicable regulations. This consulting firm verifies compliances with existing and emerging regulations. The client maintains a system to ensure that required permits and authorizations are obtained and maintained current. The client will continue to coordinate with local authorities to expedite, to the extent possible, the issuance of all permits and authorizations by municipal, provincial and federal agencies. At each facility, results of environmental and health and safety monitoring programs are reviewed by various department and reported to the EHS manager and reported to authorities. In addition, at some facilities (e.g. Cañuelas Plant and Spagezzini Plant), environmental authorities also conduct independent monitoring of effluent quality to ensure that the treated effluents do not degrade the quality of surface water bodies.
Policy - Molca is guided by a high-level vision and mission statements establishing the key objectives and pillars of credo of the organization. The EHS Policy covers overarching environmental, health, safety and quality principles and commitments that apply to all industrial processes of the business. The policy considers achieving sustainability and maintaining employee and customer satisfaction, core to its success. The policy is aligned to GIIP, including policy requirements in the IFC Performance Standards.
Molca also has a Ethical Supply Policy that prohibits the use of forced and child labor in its supply chain, and promotes a process for mapping and ensuring that these are not located in key biodiversity or sensitive areas. In recent years, Molca has hired the services of a third party independent consultant based in Brazil to map and geo-reference its supply chain to make sure these are not sited in high risk areas, in line with its policy.
Identification of Risks and Impacts - The client has a process for periodically identifying, assessing and reviewing ESHS risks and impacts of its industrial and origination activities, including those resulting from the work done by contractors and its supply chain. The risk assessment is maintained by the EHS team, who in turn, is responsible for liaising and communicating with the production, operations and maintenance teams, to ensure all risks and impacts are mitigated in a phased manner.
For new projects, the client has an internal requirement to prepare environmental and social impact assessments (ESIAs) describing the environmental and social conditions at the site(s), identifying ESHS risks and impacts and providing preventive and mitigating measures, as well as an appropriate management plan. For example, the newly built (2014) Spagezzini Plant underwent the ESIA process, and was designed with state of the art production equipment, following GIIP. In older operations like its flagship location Cañuelas Plant and Pigue, where ESIA’s were not required since they were existing plants when they were acquired, the client used a process of internal and independent inspections and audits to verify workplace conditions as well as conditions of key equipment. The Cañuelas Plant is the largest and most complex of all plants, as it is not only the oldest but it also includes cooking oil production which is a process that requires large volumes of water and generates oily smoke and mist emissions as well as large volumes of effluents. At this plant, the client has rightly identified EHS risks associated with the old electrical system and chemical storage tanks and has developed an action plan to upgrade these systems. Molca has conducted audits to verify the conditions of all systems and equipment (e.g. electrical systems, surface drainage system around areas that store chemicals and fuels, boilers, chemical storage tanks, fire protection pumps, etc.) at older facilities and has developed action plans to improve conditions or upgrade systems and equipment in a phased manner, following a hierarchical mitigation strategy based on prioritization of issues.
While Molca has several controls in place to manage environmental and social risks and impacts of its supply chain (origination activities), it lacks an integrated supply chain management policy and plan. Molca will develop a supply chain management policy and plan compliant with IFC PS 2, supply chain requirements in the EHS Guidelines on Annual Crops, and aligned with the PS2 Handbook for Labor and Working Conditions, “Measure and Improve Your Labor Standards Performance”. ( ESAP Condition 1) The Plan will include a supply chain screening questionnaire for all new producers being considered by Molca. The questionnaire will include questions around the producer’s own supply chain, making sure these are also subject to Molca’s Ethical Policy requirements. ( ESAP Condition 2)
Management Programs - In alignment with GIIP and the requirements of the various ESHS management systems that the client has already implemented, Molca implemented the following key management programs: (a) Solid Waste Management; (b) Water Quality Monitoring; (c) Fire Protection System; (d) Emergency Preparedness and Response; (e) Effluent Treatment and Effluent Quality Monitoring; (f) Air Emission Monitoring; (g) Hazardous Material Management; (h) Pest Control Management; (i) Work Place Conditions (noise, vibration, temperature, illumination); (j) Worker’s health/medical surveillance; (k) Traffic Management Plan; and (l) Community Engagement Program.
These programs, along with others, are managed in a systematic manner, aligned to GIIP and the IFC PS requirements. Implementation of these programs is through a combination of various departments at each plant, including production, quality control, laboratory, maintenance, environmental, and health and safety. Verification is done through the series of internal, inter-plant and independent audits. Management programs are consistent with the nature and scale of risks and impacts at each plant.
For origination activities, Molca will carry out a gap analysis analyzing its alignment with the new EHS Guidelines on Annual Crops, which includes specific activities for the supply chain, and will enhance its management programs to fill any gaps between these. ( ESAP Condition 3)
Organizational Capacity and Competency – Molca is managed and operated in accordance to the terms and conditions set out in its Corporate Governance Manual. The manual establishes the current organizational structure of the business, and publicly defines each person’s roles and responsibilities. Molca is headed by an Executive Team, in turn supported and guided by four executive committees (i) management, (ii) internal audit, (iii) risk management, and (iv) sustainability. The General Manager assumes responsibility for managers at the plant (operational) level. The Company has proven experience and track record in the industry, demonstrating that its business approach is balanced, keeping with sustainability principles accepted by GIIP and the IFC PS.
In 2013, with support from top management and the President of the Group, the EHS manager made a strategic decision to align its integrated EHS management system to the IFC Performance Standards (PS), thus going above and beyond requirements of its international certifications andlocal regulatory requirements in respect to management of ESHS. Teams of EHS specialists were hired at each of the industrial plants and facilities, allowing for Molca to begin implementing the new IFC PS compliant ESMS in 2014. Engagement with internal and external stakeholders is managed by the Communications Team, in coordination with the HR and EHS Teams.
Emergency Preparedness and Response - Over the past three years, as the client developed and implemented its integrated ESHS management system and sought certifications, the client improved previous procedures and processes to identify EHS risks at its facilities. Emergency Preparedness and Response (EPR) plans have been developed for each facility and improvements are ongoing. Consistent with good practices, the EPR plans were developed based on the identification of occupational health and safety hazards at each plant. At the Spagezzini and Cañuelas plants, where ammonia is used in the refrigeration system, the client has developed specific EPR procedures and conducts drills related to ammonia leaks. Molca has employed good practices to prevent potential leaks, including scheduled maintenance of the system by qualified contractors and continuous air quality monitoring in the areas where ammonia is used. At all plants, the client has trained brigades and EPR personal protective equipment (PPE) for the specific emergencies (e.g., firefighting PPE, ammonia leak PPE, first-aid, personal meters to measure ammonia concentrations in the air, oxygen concentrations, etc.). In most plants, drills are conducted in coordination with local fire departments, but the client is working toward having drills in coordination with local fire department at every location. Where communities are near the plants, Cañuelas has developed procedures to communicate with communities to ensure their safety in the event of a major emergency. As part of continuous improvement practices, Molca has conducted additional evaluations of EPR procedures, personnel qualification and training needs, equipment and PPE and has developed an action plan to improve ERP at each facility, along with a detailed and rigorous schedule for drills.
Monitoring and Review - With the objective of understanding EHS performance indicators at each facility, the client has implemented EHS monitoring programs that are tailored to the operations at each plant. EHS performance indicators are reviewed by several departments including Quality Control, onsite laboratory, plant maintenance, and onsite EHS personnel. The EHS performance indicators are reported to the corporate EHS manager who shares the key information with the Company’s directors. The audit program that evaluates the monitoring programs include: (a) Annual internal audits; (b) Annual inter-plant audits; (c) Regulatory compliance conducted by Estrucplan every six months; (d) Certification audits conducted by SGS; (e) Medical surveillance conducted by the insurance company; (f) SEDEX (ethical trade audits); (g) Audits by the local environmental agency to ensure compliance of treated effluent quality: and (h) Non-compliance matrix used to monitor implementation of corrective action plan.
Overall, the client has developed and implemented a monitoring and review program that is consistent with good international practices.