C226 - Napier Leathers Ltd, Napier - Hawkes Bay
Region
Summary
A willingness by Napier Leathers to review and redesign existing processes
resulted in the identification of savings greater than $470,000/annum. Looking "up-the-pipe" at
the source of waste yielded benefits much greater than what was initially
thought and demonstrated the value of thinking "outside the square".
Business Profile
Napier Leathers processes pickle and wet blue and deerskins into a wide variety
of finished leathers that are marketed to the world fashion industry for
manufacturing into garments, footwear and accessories.
Napier Leathers Ltd has operated as a stand-alone
company since January 1998. Prior to this time it was a division
of the Napier
Tanning Company Ltd. In 1999 a decision was made by the company’s
overseas owners to relocate Napier Leather’s value adding operation
offshore, resulting in the closure of the Napier plant.
Type of Projects
Process redesign and chemical substitution
Reasons for Projects
To be successful in what is a competitive industry it was
recognised that Napier Leathers must become more efficient in
all aspects of production. Waste reduction was identified as
an area where Napier Leathers could improve its competitiveness.
Not only is it an environmental responsibility it is also sound
business sense as waste is cost. Napier Leathers became a member
of the Target Zero project in the Hawkes Bay to help realise
this responsibility and focussed on the key areas of water use
and solid waste containing chrome, identified by a preliminary
waste assessment.
Only the water related project was completed as the plant closure
was announced before the solid waste project was implemented.
Target Zero
Napier Leathers Ltd has been a participant in Target Zero, a two-year sponsored
cleaner production programme involving 12 companies in Christchurch and 10
in Hawkes Bay during the period 1997-1999. The programme was sponsored by
the Sustainable Management Fund of the Ministry for the Environment, Meridian
Energy Ltd (formerly ECNZ), and the local authority and electricity company
in each area.
The Projects
The compact process
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Description
|
Metering of water use around the Napier Leathers plant
identified two areas where most of the water was used.
It was decided to focus on the retanning and dyeing process,
being the area where plant staff had most knowledge and
technical expertise.
Initial tests to see if water minimisation was possible
by reducing the number of process washes were not promising.
At this point it was decided to review the whole processing
method and question whether it was the most efficient and
environmentally friendly system.
Napier Leathers then adopted a preventative
approach by developing a "compact" process that reduced the
need for as many washes in the first place. The redesign
of the process required a review of all the components
of the process, in particular the compatibility and exhaustion
(how much chemical is "fixed" to the skin) rates
of the chemicals used.
While the main focus was on water reduction, considerable
trial work was required to ensure that leather quality
would not be negatively affected and that the new system
would be at least as cost effective as the old process.
Although the initial objective was to reduce water use,
a relatively low cost resource in Napier, substantial savings
were realised in chemicals, electricity and labour. The
greatest cost savings were in chemicals. |
|
Environmental Benefit
|
47% reduction in water use.
45% reduction in electricity use
|
|
Other benefits |
More efficient use of operator time |
|
Economic Benefit |
Capital cost None (staff development
time only)
Savings $470,170/annum
Payback Immediate |
Solid waste containing chrome
|
Description
|
A mass balance identified the solid waste produced by
removing excess substance from pelts during processing
was a significant issue. Because the pelts are difficult
to handle and machine without chemical addition, the shaving
and trimming of the pelts has traditionally been done after
the skins have been tanned with chrome. As a result the
solid waste produced was chrome contaminated.
The only way to reduce the solid chrome trim and shaving
waste was to machine the pelts before the chrome was added.
In order for this to be successful a substitute chemical
had to be found that was inert, inexpensive and had no
adverse environmental impact.
Several inert "fillers" were
trialled that allowed machining prior to chrome addition,
with the product finally
chosen being a by-product of the food industry.
Although a semi-production trial was undertaken, the full
implementation intended for September 1999 was abandoned
as a result of the announced plant closure. |
|
Environmental Benefit
|
Elimination of chrome contaminated pelt trimmings and
shavings.
Chrome free skin tissue suitable for rendering into stock
food and tallow. |
|
Other benefits |
Increased yields as a result of machining before chrome
addition |
|
Economic Benefit |
Avoided landfill costs and returns from renderable raw
material.
Improved return as a result of increased skin yield. |
|
For additional information contact:
Napier
Phone (06) 835 6085
Fax (06) 835 0404 |
For further information about the Target Zero programme
see following publication:
- You too can profit from cleaner production
and waste minimisation
Coordinating cleaner production programmes. Lessons from
Target Zero |
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