3 nyanza bottling company limited - cpct photo/beverage industries.pdf · 3 nyanza bottling company...

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Resource Efficient and Cleaner Production (RECP) - Case Studies

3 NYANZA BOTTLING COMPANY LIMITED

3.1 Overview

Nyanza Bottling Company Limited (NBCL) is a subsidiary company of The Sumaria Group of Companies, located at Nyakato industrial area along Nyerere road in Mwanza City. The company was set up in 1987 and currently employs over 1000 people directly and provides indirect employment to more than 4,000 people. The Company produces and distributes carbonated soft drinks (CSDs) and non-carbonated beverages packaged in refillable glass bottles (RGB) and plastic bottles (PET). The company has over 13000 outlets and serves over 12 million consumers in six regions. NBCL being a participant of the training workshop conducted by Cleaner Production Centre of Tanzania (CPCT) regarding Resource Efficient and Cleaner Production (RECP) for enterprises and stakeholders in Lake Victoria Basin adopted the RECP concept. To protect “The Coca-Cola Company Trade Mark” NBCL has put in place The Coca-Cola Management System (TCCMS), which integrates quality, environment and occupational health and safety.


253.2 Benefits

The implementation of RECP at NBCL has brought about efficiency in utilization of its resources. From 2011 to 2013, vital improvements have been experienced such as: reduction in specific water consumption by10% in year 1 and 39% in year 2; minimization of waste water generation by 10% in year 1 and by 29% in year 2; cutting down of electricity consumption by 39% in year 1 and 67% in year 2; minimization of waste water generation by 10% in year 1 and 29% in the year 2; increase in energy productivity by 50% in year 1 and 137% in year two, increase in material productivity by 5% in year 1 and 2% in year 1. Reduction in air pollution by 39% in year 1 and 67% in year 2; CO2 intensity was reduced by 33% in year 1 and 58% in year 2; reduction of BOD levels from 23.0 to 17.0 mg/l and increasing of line of efficiency by 3%. In addition to that, effluents are being discharged in environmentally safe manner. The company participated in the 2013 National RECP Awards competition and won as an overall winner in the Waste Water Management, first runner-up in Water Use Management and Energy Efficiency Award categories. Similarly NBCL participated in the 2014 Regional RECP Awards competitions and won in the Waste Water Management category as first runner-up.

Table3:1:ResultsataGlance

Absolute Indicator

Change (%) year 1

Change (%) year 2

Relative Indicator

Change (%) year 1

Change (%) year 2

Resource Use Resource Productivity Energy Use -39 -67 Energy Productivity 50 137Materials Use -4 -23 Materials Productivity -5 2Water Use -10 -29 Water Productivity 2 2Pollution Generated Pollution Intensity Air Emissions (global warming, CO2 eq.) -39 -67 Carbon Intensity -33 -58

Waste Water -10 -29 Waste-water Intensity -2 -10Waste 19 -16 Waste Intensity 31 6Product Output -9 -21

Note: Absolute indicators provide a measurement of how much resource use/pollution output has changed in absolute terms e.g. units of energy used or tons of waste generated. A negative percentage indicates a decrease and a positive percentage indicates an increase. Relative indicators provide a measurement of changes in resource use/pollution in relation to production output. Resource productivity provides a measurement of how much product output can be produced per unit of resource use, from a sustainability perspective, productivity should increase. Pollution intensity provides a measurement of how much pollution is generated per unit of production output, from a sustainability perspective, intensity should decrease.

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3.3 RECPProfile

Note: The RECP profile provides a visual overview of resource productivity and pollution intensity shown as change in percentage compared to the baseline values. Environmental performance is improved when resource productivity increases and when pollution intensity decreases.

3.4 AreasofImprovement

The management of Nyanza Bottling Company Limited is highly committed to assure efficient utilization of its resources by keeping waste generation at minimum and productivity at maximum, through implementation of Cleaner Production options. The company has implemented most of the CP options i.e. materials are purchased from approved suppliers/manufacturers by the Coca-Cola Company; recycling of solid waste from packaging material such plastic containers, crates and bottles pre-forms are crushed and sent back to the supplier; modification of processes i.e. recycling of caustic solution from the bottle washer; installation of automatic filler machine for syrup and water mixing; installation of Agro (biomass) boiler to reduce the use of the HFO and installation of furnace oil containment and oil separator. Others include: installation of push taps in the washrooms; construction of a wastewater treatment plant; installation of overheads tanks in the public toilets to minimize bursting and leakages of pipes; introduction of using water guns/nozzles during cleaning; construction of a 100 m3 tank for storing recycled water from bottle washers; installation of flow meters to continuously monitor and quantify the effluents from the plant’s operations. The implementation of RECP options also enabled improvement in Corporate Social Responsibilities e.g. involvement of the factory in: planting trees under green fields to communities in schools, construction of health centres, installation of bore halls for schools, provision of services for treating eye cases.

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Table3:2:OptionsImplemented

Principal Options Implemented

Benefits

Economic Resource Use Environmental impact

Investment [USD]

Cost Saving [USD/yr]

Pay Back Period Reductions in

energy use, water use and/or materials use (per annum)

Reductions in waste water, air emissions and/or waste generation (per annum)

Water Managementa) Recycling of

vacuum pump of blender cooling water.

1,625 21,375 15 Days Reduced water cost

Reduce waste water generation and treatment cost.

Minimize waste water generation.

b) Recovery of backwash water

c) Recovery of condensate

500 5,700 30 Days Water use Reduction

d) Construction of gutters that would collect rain water to minimize municipal water usage.

1,062.5 1,140 30 Days Reduced resource use

e) Construction of 1600 m3 tank which provide savings in terms of materials, energy, water, disposal

115,625 62,500 48 months Reduced water

cost

f) Installation of water meters in potential areas of water usage.

Improved water management

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Benefits


Investment [USD]





Wastewater Management

a) Installation of Effluent Treatment Plant which recycle process water

b) Reducing daily water consumption,

c) Metering of waste water.

d) BOD and COD monitoring/quantification

104,375 135,386 8months Reduction in raw water usage by 40%

COD decreased from 90.5mg/l to 25.9 mg/lCompliance to Legal requirement.

The company has an internal lab for environmental monitoring plan

Pollution conc. (mg/l)

2010 2014

BOD 667 24

COD 2769 42

TN 38 2

TP 11 1

Materials Management

a) Rearrangement of material storages: pre-forms, cartons, sugar, concentrates, glass, pallets, crates, auxiliary materials.

b) Caustic solution recycling after washers draining

66,273 10,968 6 yrs

Building of additional godowns helps to avoid materials congestion and facilitate traceability &GMP Compliance

Proper utilization of detergent

Reduce ETP load

Reduce waste water generation.

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Benefits


Investment [USD]





Energy Management

a) Technological changes from heavy furnace oil to biomass (Agro waste) boiler.

b) Condensate recovery optimization and monitoring.

c) Installation of electricity meters on both piece of equipment

70,687.5 368,576.5e.g. As per 2011 consumed 500,000l of HFO which cost TZS 750m. In 2013 consumed 1,600,000 kg of cotton husk & Saw dust which cost TZS 192m.

Reduced consumption of HFO

Electrical Meter Installed in each bottling facility in order to monitor power consumptions.

Reduction of CO2 emission by 67%

Reduced global warming

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Benefits


Investment [USD]





Solid Waste Management

a) Pallets are repaired and reused, those which cannot be repaired are used as fire wood in the kitchen and the agro boiler

b) Crates that cannot be repaired are crushed and returned to the supplier/manufacturing company

c) Glass bottles that cannot be used/broken are crushed and returned back to the supplier/manufacturing company

7,500

625

69,316

82,268

2months

1week

Reduced amount of agro waste

Reduced solid waste

Improved solid waste management.

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Benefits


Investment [USD]





Air emissions

a) Installation of a crate conveyor which eliminate the use of forklift

The over head conveyor supplies glass float for line 2 operations.

b) Installation of sugar belt conveyor to eliminate use of forklift.

The conveyor help to speed up operations of syrup making, better inventory control and safety.

70,000

71,250

18,750

8,000

4yrs

7yrs

Reduced fuel consumption.

Reduced fuel consumption

Reduced emissions

Improved safety

Others

a) Introduction of a new technology for bottles inspection (electronic bottle inspection system - EBI).

b) Automation of washers on lines two and four.

Improved consumer satisfaction.

Reduced energy use

Total 509,523 783,979.5

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3.5 Illustrations

(a) A HFO boiler (b) An agro (biomass) boiler

(c) Before installation of water recovery system

(d) Vacuum cooling water recovery installed

(e) Water Storage tanks installed (f) Waste water treatment plant

(g) Ablution block that use treated Effluent (h) Reuse of treated water Effluent


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(i) Crashing of plastic materials (j) crashed plastic materials in bags

(k) The mechanical glass crusher (l) Crushed glass bottle ready for recycling

(m)Overhead crate conveyor (n) Sugar Conveyor

(o) Additional godowns for materials storage.

(p) A Caustic Recovery plant

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3.6 ApproachTaken

The success in implementation of RECP at NCBL was necessitated by formation of a task force through which Cleaner Production concept was integrated in the Coca Cola Management system (TCCMS). Responsibility of the task forces were to:- create awareness of RECP concept to top management; train more workers on the RECP Concept; compile report for management review; plan action and audit of every unit operation within the company so as to identify the weakness. Technical, Environmental, and economical evaluation of the options were undertaken basing on investment cost involved and payback period. Obvious waste streams were addressed immediately.

The NBCL is working out to continually implement and maintain the RECP program in the company through the following initiatives: creating awareness to all workers and stakeholders on the importance and benefit of Cleaner Production; updating RECP assessment report as and when need arises particularly if there is substantial change of the basic parameters and /or technology; collaborating with other industries for information exchange and learning of useful experiences; Regularly monitoring of the implementation of cleaner production and evaluating results as per approved performance indicators in the company; and integrate RECP with other functions (EOSH) for auditing and documenting preventive and correction action plan.

3.7 BusinessCase

The NCBL has become a reliable company with its products acceptable by consumers in all the six regions supplied by the company. The company gained trust through its initiatives in providing high quality products and services as a result of effective implementation of Cleaner Production options. Finally, the company acquired some recognition awards for being the best performer in provision of high quality services. Currently there is a very great demand for fruit juices. The company has planned to start producing several brands of juices like minute maid and canned products. It has also introduced PET carbonated soft drinks which are in the market.

3.8 ContactInformation

Formoreinformationpleasecontactthefollowing.Company contact Name: NyanzaBottlingCompanyLtdP.O.Box: 20086, Mwanza

Contact PersonName: Mr.PeterSimonTel: +255784800709Email: [email protected]

RECP championPeterSimon, +255784800709

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4 SERENGETI BREWERIES LIMITED (SBL), MWANZA PLANT

4.1 Overview

Serengeti Breweries Limited (SBL) Mwanza Plant is a company dealing in beer production located at Nyakato Industrial area in Mwanza, Tanzania. The company was established in 2006 starting with brewing two brands of beer namely, Serengeti Premium Lager and The Kick. The plant has now expanded its brand portfolio that goes in line with SBL expansion drive. Currently brands brewed at SBL Mwanza plant include; Serengeti Premium Lager, The Kick, Uhuru Peak Lager, Pilsner, Tusker Lager and Senator. The current production capacity of the plant is 500,000 HL per annum.

The company also has Tusker malt Lager, Tusker light Lager, Kibo gold, Guinness stout, Alvaro Malta Guinness and spirit brands which include; John Walker, Gordons, Smirnoff Vodka, Gilbeys gin, Richot Brand and Baileys Irish Cream which are produced by other SBL branches.

Currently, Mwanza Brewery has employed about 329 people of whom, 172 are SBL Staff while 157 are contract workers.

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4.2 Benefits

Serengeti breweries Limited started RECP implementation in 2011 after receiving training from the CPCT. Implementation of several RECP options in energy management such as; switching off lights during the day time; control of ACs usage; replacement of 30kW air compressors by 7.5kW air compressor when there is no production and replacement of steam condensate traps have enabled the company to achieve a significant reduction in energy consumption which resulted into an annual saving of USD 284,000. Also the company was able to save USD 7200 through implementing water management options like using ETP water for gardening, installation of push taps for the urinals in men toilets, training of employees on proper use of water and re using of backwash water in toilets.

RECP concept also has complimented the construction of Effluent Treatment Plant (ETP) at the factory that improved the quality of waste water generated and hence attaining the environmental compliance. Initially the company was spending about Tshs 300 – 400 million per month (equivalent to USD 300,000 per year) for disposal (collection and transportation) of wastewater to Municipal wastewater treatment facilities. The construction of ETP within the industry premises has eliminated this cost.

Likewise, air emissions have also been reduced by 19% as a result of reduction in the use of fossil fuels and good production plan i.e. use of small machines when producing less. The company participated in the 2013 National RECP Awards competition and won in the categories of Waste Water Management and Water Use Management as first runner-up and second runner-up respectively.

Table4:1:ResultataGlance

Absolute Indicator

Change (%) Follow-up 2011


Relative Indicator Change (%) Follow-up 2011


Resource Use Resource Productivity

Energy Use -10 -23 Energy Productivity -10 2

Materials Use -27 -36 Materials Productivity 11 23

Water Use -20 -33 Water Productivity 1 16Pollution generated Pollution Intensity

Air Emissions (global warming, CO2 eq.)

2 -19 Carbon Intensity 26 4

Waste-Water -31 -42 Waste-Water Intensity -15 -26

Waste -34 -44 Waste Intensity -19 -28Product Output -19 -22

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Note: The absolute indicator provide a measurement of how much resource use/pollution output has changed in absolute terms e.g. units of energy used or tons of waste generated. A negative percentage indicates a decrease and a positive percentage indicates an increase. The relative indicator gives a measurement of changes in resource use/pollution in relation to production output. Resource productivity provides a measurement of how much product output can be produced relation to resource used, from a sustainability point of view, productivity should increase. Pollution intensity provides a measurement of how much pollution is generated per unit of production output, from a sustainability perspective, intensity should decrease.

4.3 RECPProfile

Note: The RECP profile provides a visual overview of resource productivity and pollution intensity shown as change in % compared to the baseline values. Environmental performance is improved when resource productivity increases and when pollution intensity decreases.


Beer production process uses water as raw material and utility. Before implementation of RECP concept, the company was using high amount of water and generating significant amount of waste water. The implementation of several RECP options in both water and waste water management has lead to reduction in water usage and waste water generation by 33% and 42% respectively.

With regard to energy management, the RECP concept has helped SBL company to develop some best solutions in improving efficient use of energy, hence minimization of energy consumption by 23%.

The company also focused on improving efficient use of materials as well as reduction of air emissions.

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Table4:2:Optionsimplemented


BenefitsEconomic Resource Use Environmental Impact

Investment [USD]


Reductions in energy use, water use and/or materials use (per annum)


Water Management

•Use ETP water for gardening

625 9,000 Reduction in water consumption by 61,658m3 (33% reduction)

Reduction in waste water generation by 61,658m3

•Installation of push type taps on men toilets (urinal)

1250

•Training of employees on proper use of water especially cleaners (dry cleaning approach)

•All plant CIP reviewed and water consumption reduced

•Having water balance in place

•Re using of back wash water in toilets

•Isolation of water on weekends.

•Daily checklist to monitor water leaks around the plants including toilets.

•Reporting daily water usage to the management in morning production meeting.

Management action at no cost

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Investment [USD]




Waste water Management

• Construction of WWTP 6,000,000 812,500

The company is in the final stage to be certified under ISO 9001

• Controlling of water usage which resulted into minimal waste water generation

• Measuring and reporting waste water

discharged from site on monthly basis


Pollution conc. (mg/l)

2011 2014

BOD 2500 20

COD 3430 48

TSS 599 69

pH 11 8


• Scheduled pest control program (Fumigation) in place

• Use of internal requisition notes to request for materials from the store for the purpose of controlling its usage

• Monthly stock taking and reconciliations in place to monitor material usage

• Use of SAP system to provide transparency for material usage

• FIFO (First in First Out) system in place to avoid losses due to expiring


Reduction in material use by 36%

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Investment [USD]




Energy Management• Ensure brewing and

Packaging run together to have utilities running efficiently for both at same time

• Having environment tracker on key environment areas that need focus each year for the purpose of resource savings and improvement

• Optimization of ETP plant by switching off Aerobic reactor1for energy use minimization

• Switching off all rights during the day time, control of AC usage, and creating awareness to employees on proper use of energy

• Small Air compressor (7.5Kw) in use to replace that of 30Kw on weekend when there are no production operations.

• Steam condensate traps replaced in the brewing section (high steam use area) for recovering condensate.

• Reviewed CIP regime to cut down power usage.

• Checklist in place to monitor air and steam leaks

• All managers shifted in one office and other rooms closed for the purpose of cutting down power costs from ACs and lights.

• Having efficiency motor policy in place which is used during the purchasing of new Equipments/motors/pumps






72,942.75


8,625

12,875

8,500

248,625

5,375

Reduction in energy use by 23%

Reduction in Carbon dioxide emissions by 19%

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Investment [USD]




Air emissions

• Good production planning e.g. use smaller machines when producing less

• Reducing the use of fossil fuel where necessary

Management action at no

cost

Reduction in air emissions by 19%

Total 6,074,817.75 1,105,500

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4.5Illustrations

Before treatment; BOD=2500mg/l , COD=3430mg/l , TSS=594mg/l and pH=11

After treatment; BOD=20mg/l, COD=47.9mg/l, TSS=69.1mg/l and pH=8.1mg/l

Before RECP Training After RECP Training

Before construction of ETP ETP in place

The tanks installed to store recovered and recycled back wash water Clearly labelled waste bins

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4.5Illustrations

Before treatment; BOD=2500mg/l , COD=3430mg/l , TSS=594mg/l and pH=11

After treatment; BOD=20mg/l, COD=47.9mg/l, TSS=69.1mg/l and pH=8.1mg/l

Before RECP Training After RECP Training

Before construction of ETP ETP in place

The tanks installed to store recovered and recycled back wash water Clearly labelled waste bins

4.6 ApproachTaken

Resource Efficient and Cleaner Production (RECP) concept was introduced at SBL Mwanza plant in 2011. The training received from CPCT was an important tool to motivate the company to use its resources more efficiently. It was easy for the company to implement the RECP concept because the CPCT training came at the time when SBL was undergoing transformation in the management of its operations which was in line with the RECP ideals.

4.7 BusinessCase

Due to the use of the RECP approach as a tool to address resource efficiency, pollution reduction, and health and safety issues, SBL business keeps growing day by day and it has helped the company to improve its image in the community, government and to other stakeholders. Above all, it has enabled the company to become more competitive in business.

4.8 Contactinformation

Formoreinformationpleasecontactthefollowing.

Company contactsName:SerengetiBreweriesLtd–MwanzaPlantP.O.Box:11665, Mwanza

Contact PersonName:AnnaMangaraDesignation:EnvironmentalSpecialistTel: +255782782888 Email:[email protected]

RECP championAnnaMangara:+255782782888

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6 TANZANIA BREWERIES LIMITED-MWANZA PLANT

6.1 Overview

Tanzania Breweries Limited Mwanza plant is one of the leading producers of alcoholic beverage in Tanzania. The company is located at Pasiansi, Ilemela Municipality in Mwanza City along the shore of the Lake Victoria. It was established in 1995 with a production capacity of 772,000 HL of clear beer. The plant brews a variety of beer including Safari Lager, Kilimanjaro Premium Lager, Ndovu Special Malt, Eagle Lager, Balimi Extra Lager, Castle Lager, Castle Milk Stout and Castle Lite. TBL Mwanza also runs an opaque plant which produces quality local beers, Nzagamba and Chibuku Super brands. The plant sells other categories of alcoholic and non-alcoholic brands produced in other plants in Tanzania. These are Redds Premium Cold, Peroni, and Club 07 (Vodka). Non-alcoholic brands are Grand Malt and Safari Water.

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6.2 Benefits

Tanzania Breweries Limited started RECP implementation in 2010 with the main objectives of, reducing water and energy usage, waste minimization, operational costs reduction, global sustainability compliance as well as improving business image. Since knowing that RECP is a basic tool for achieving financial savings and environmental benefits, the management of TBL commited effectively in the implementation of the RECP concept at the factory by formulating a RECP team which started implementing RECP immediately. Execution of the RECP at the factory has enabled the company to obtain an equivalent annual savings of USD 37,500 if it was to pay for water bills, more than USD 56,250 in energy consumptions, reduction of Carbondioxide emissions by 50% , reduction of solid waste generation by 39% as well as reduction of waste water generation by 42%. The company participated in the 2013 National RECP Awards competition and won as an overall Corporate winner, overall winner in the Water Use Management and Energy Efficiency as well as second runner-up in the Waste Water Management Award categories. TBL also participated in the Regional RECP Award competitions in 2014 and emerged as an overall Corporate winner and overall winner in the Water use Management and Energy Management categories.

Table6:1:ResultsataGlance

Absolute Indicator

Change (%) year 1

Change (%) year 2

Change (%)year 3

Relative Indicator

Change (%) year 1

Change (%) year 2

Change (%)year 3

Resource Use Resource Productivity

Energy Use -12 -11 -44 Energy Productivity 13 7 74

Materials Use -22 -40 -74 Materials Productivity 28 58 283

Water Use -24 -44 -56 Water Productivity 31 2 122Pollution Generated Pollution

Intensity

Air Emissions (global warming, CO2 eq.)

1 -23 -50 Carbon Intensity 2 -19 -49

Waste Water -25 -35 -42 Waste-water Intensity -24 -32 -41

Waste 6 -24 -39 Waste Intensity 7 -20 -38Product Output -1 -5 -2

Note: The absolute indicator provide a measurement of how much resource use/pollution output has changed in absolute terms e.g. units of energy used or tons of waste generated. A negative percentage indicates a decrease and a positive percentage indicates an increase.

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The relative indicator gives a measurement of changes in resource use/pollution in relation to production output. Resource productivity provides a measurement of how much product output can be produced relation to resource used, from a sustainability point of view, productivity should increase. Pollution intensity provides a measurement of how much pollution is generated per unit of production output, from a sustainability perspective, intensity should decrease.

6.3 RECPProfile

Note: The RECP profile provides a visual overview of resource productivity and pollution intensity shown as change in % compared to the baseline values. Environmental performance is improved when resource productivity increases and when pollution intensity decreases.


Due to the nature of production, energy and water usage are the main areas which contribute to high operation cost of the factory. Implementation of RECP options in energy management has enabled the company to achieve 44% reduction in total energy consumption, this was mainly achieved through replacing higher energy consuming lights with energy saver ones, insulation of steam and condensate lines, utilization of energy efficient motors, application of energy saving compressors as well as improved condensate recovery from 60% to 85%.With regard to water usage, implementation of water management options like condensate recovery, installation of water sub-meters, backwash water recovery system, CO2 Scrubber water recovery, vacuum pump water recycling, installation of water guns and weekly water leakages checklist has enabled the company to reduce its water daily consumption from an average of 5,804,639.00 Hectolitre/yr in 2011 up to an average 2,571,383.00 Hectolitre/yr in 2014 which is more than 50% reduction.

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Table6:2:Optionsimplemented


BenefitsEconomic Resource

UseEnvironmental Impact

Investment [USD]


Payback period



Water Management

• Condensate recovery

• Wash room upgrade

• Backwash water recovery

• Water meters installation

• Water guns

• Domestic water main ring upgrade

• CO2 Scrubber water recovery

• Bottle washer new sprayers

• Vacuum pump water recycling

USD 112,500 USD 37,500

3 years Reduction in water use by 3,233,256.00 Hectolitre

Reduction in waste water generation by 3,233,256.00 Hectolitre

Wastewater Management

• Recycling water

• Daily water consumption reduction

• Waste water metering

Included in the water management investment costs

Reduction in waste water generation by1,612,909Hectolitre (eq. to 42% reduction)

Pollution conc. mg/l)

2010 2014

BOD 940 217

COD 1192 444

TN 10 7

TP 7 6.8

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Investment [USD]


Payback period




• Proper material storage

• Process optimization

• Better quality materials usage.

Normal operational cost

Reduction in material use by 426,461.41 tones

Reduction in waste generation

Energy Management• LED lights

installation• Process optimization• Steam and

condensate line insulation

• Improved condensate recovery

• Utilization of energy efficient Motors

• Application of energy saving compressors

• Proper control of energy equipment during day time and during off days.

USD 104,375 USD 61,250

1.7 years

Reduction in energy use by 57,170,856.40 MJ

Reduction in carbon dioxide emissions (4,458 tons-equivalent to 50% reduction)

Solid Waste Management•Machine replacement•Bottles replacement•Goal setting

Reduced bottle breakages

Reduced machine downtime

Reduction in solid waste generation by 2,895.20 tons Reduced solid waste caused by bottle breakages

Air emissionsTechnological changes from heavy furnace oil to biomass boilers

Reduced heavy furnace oil usage

Reduction in Carbon dioxide emissions (4,458tons-eq to 50% reduction)


56Principal Options Implemented



Investment [USD]


Payback period



Process Optimization Management System installation

-Montage tool

Quality Parameters Control

•SIC

•PMC

•PIMS&POMS

USD 54,000

USD 800

1 year Software used to provide insights into water & energy trends, deviations & performance

Used to track process parameters deviations and assist in quick response to deviations

Total 271,675 98,750


576.5 Illustrations

BEFORE RECP AFTER RECP

Security light (1000W) Solar light security system

LED lights (100 W) LED Lights ( 10, 20 W)

Old pasteurizer New pasteurizer


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New bottle washing machine

Water metering

Water gun for cleaning

5959


6.6 ApproachTaken

In 2010, TBL realized the importance of adopting RECP concept in order to acquire potential techniques and approach on how to handle water usage, energy and materials consumption more efficiently and reduce air emissions and waste generation.

In collaboration with the CPCT, the company started implementing RECP by first training two key staff in RECP concept, its implementation and benefits. The two trained staff formed a RECP team which comprised 10 members drawn from various sections/departments. The main task of the RECP team was to analyze the present operational status in terms of resource (water, energy and materials) consumption by conducting waste and lose analysis and mass balance using the RECP toolkit.

After realizing the benefits of RECP, the company decided to dedicate some funds for the implementation of RECP projects and established a special task force called Sustainable Development Team to strategically oversee the activities of the RECP team.

6.7 BusinessCase

Achievements obtained from the implementation of RECP have enabled the company to improve its operations by increasing its resource productivity, getting high quality products and reducing pollution load. The benefits realized by implementing RECP options have made the company more competitive in business, and have enabled it enhance its Corporate Social Responsibility contribution, environmental compliance and overall image in the community.

6.8 ContactInformation

Company contact:

TanzaniaBreweriesLtd–MwanzaPlantP.O.Box661,Mwanza

Contact Person:Name:Mr.RichmondRaymondDesignation:PlantManagerEmail:[email protected]: +255767266930Fax: +255222111579

RECP Champions:1.JohnLugongo ProcessEngineer, +2557672667132.SundayKidoleziUtilitiesManager,+255767266596

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