Sustainable Development

Complex rationalization of water management at CEREPA a.s.

In 1998–2003, CEREPA, a.s. implemented a water management rationalization project.

The whole project was divided into three steps, which had to be taken one at a time and then evaluated before proceeding to the next so that the effectiveness of the whole project would bring the greatest savings possible while also complying with the legal requirements.

The goal of the whole rationalization process in the company was to minimize the amount of raw surface water taken from the river while also minimizing the pollution values in the outbound wastewater and complying with the emission limits set by the water management authority.

Main reasons for the rationalization project:

  • CEREPA, a.s. is located by a water management body, the Trnava River, which is affluent to the Želivka with secondary connection to the water management structure in Želivka (VDŽ) – the fundamental source of drinking water for the wide agglomeration of the city of Prague. The paper mill itself is located in the 3rd protected area of VDŽ and in close proximity to the 2nd protective area along the flow of the recipient.
  • Saving of the costs invested in the production, thus increasing the competitive capabilities of the products
  • Reduction in payments for the amount and pollution of outbound wastewater
  • The company intends to continue its contribution to maintaining a healthy environment in its neighbourhood.

Complex rationalization of water management at CEREPA a.s.

      

Lowering the power demands of production by 8 %

Energy resources are one of the three largest cost items in the production process of CEREPA, which is why we emphasize this issue a lot. In spring 2014, we initiated collaboration with VŠB – the Technical University of Ostrava, asking them to elaborate a "Technical-economical study" focused on energy savings.

Another step leading to optimising energy consumption will be the choice of provider to secure complex energy services for CEREPA.

Main activity areas in energetics

  • Purchase and delivery of energies and mediums (power, natural gas, heat and water)
  • Expertise and advisory activities in energetics
  • Operation of technological energetic units
  • Energy management
  • Energy-saving projects
  • Securing energy management activities – bill inspection, reading inspection, consumption database entries, reporting, creating a background for financial plans and other energy management activities
  • Energy management
  • Monitoring of legal obligations in the area of energetics and ensuring them
  • Dispatching management – remote oversight for buildings and technologies, emergency functionalities
  • Elaborating EA, PENB, boiler efficiency and A/C inspections
  • Preparation and implementation of energy-related project and studies
  • Purchasing power and natural gas, heat deliveries
  • Processing building passports
  • Elaborating energy concepts

Energy management – energetic management

  • Energy management deals with the economical operation of a technological system of buildings, including management of all sorts of energies
  • Its integral part is to plan and control the development of energetic management including investment intentions
  • The goal of energy management services is to deal with economically utilizable energy savings and implement the necessary technical and organizational measures that ensure cost optimisation.
  • It is a progressive approach to the management of buildings and their technologies using central dispatching to ensure the accurate functional maintenance of the interior climate, the monitoring of malfunction statuses and economical power usage.

Energy management – energetic monitoring

  • Monitors and manages the operation of selected buildings and technologies
  • Monitors and evaluates power consumption in buildings
  • Optimises power cost bases of the power demand analysis related to building operation
  • Creates a power usage database and provides situational reports on power economy development
  • Provides evidence of costs for individual mediums

With energy management, we lower the overall costs of the energy economy and the energetic demands of buildings

Monitoring and ensuring legal obligations

  • Ensures compliance with legal obligations in the areas of energetics and environment
  • Monitors changes to the legislation in question and presents reports on changes therein on a regular basis
  • Prepares a background for changes to internal legislation

EPC – Energy Performance Contracting

Energetic services with guaranteed results)
This is a complex service that provides the client with:
Proposal
Preparation
Implementation
Funding of projects resulting in energy cost savings
Principle: The initial investment is covered by future savings; energy system modifications are not a burden in terms of investments

Benefits of the offered services

  • Implementation of energy system solutions
  • Integration of all activities in the area of energetics
  • Delegating of all obligations and responsibilities in the area of energetics to expert companies
  • Reduced administrative load
  • Energy cost savings
  • Modernization of energetic devices and reducing the energetic demands of the operation

Lowering the power demand of production by 8 %

      

CNG internal filling station   

The CEREPA production site also contains a gasoline and diesel station. The fuel consumption for 2013 was 67,850 litres of diesel and 2,690 litres of gasoline. The business strategy of our company factors in the addition of new customers from the ranks of multi-national companies, the areas of car manufacturing, machinery, chemicals and processing industries. Thanks to this strategy, there will be the necessary development of logistical services covered by our own capacities. The CNG refilling station offers reduced fuel costs while also being an environmentally sound solution. In autumn 2014, we issued a task to elaborate a CN and a study for building a CNG refilling station on the premises of EON.  

CNG internal filling station

      

Paper recycling and waste treatment

CEREPA a.s. is a production organization whose main activities consist of the production and processing of paper. In terms of used raw material usage, the whole production process utilizes waste paper. This inbound raw material is purchased from providers of waste paper.

The daily capacity of the production device (the PS5 stationery machine) is approximately 31 t

of paper for hygienic purposes (toilet papers, JUMBO, paper towels).

The whole technology has the character of a closed circle, meaning the by-product waste (own excretion) undergoes reverse processing. There is an exception to this rule in the form of the paper milling sludge, which is delivered to brickyards for further utilization, as well as the sorting spoilage, which is delivered to re-cultivation production, and the pulping excretion, which is junked by authorized personnel. These wastes together represent the majority of waste produced by the company. Other waste is transported away by authorized personnel for further utilization or disposal.

The company also maintains its own natural gas boiler room to provide the required thermal energy.

Furthermore, there is wastewater maintenance, delivery and purification equipment.

The total yearly waste production is approximately 7,500 t, consisting mostly of the aforementioned paper milling sludge – approximately 7,200 t with 30 % dry mass.

There is approx. 2 t of hazardous waste produced per year.

As the originator of wastes, CEREPA a.s. is subject to the Waste Management Law (among other obligations):

  1. Sort the waste by type and category
  2. Ensure prerogative utilization of waste
  3. Only hand waste over to personnel authorized to receive it
  4. Gather waste according to type and category
  5. Protect from leaking, theft, etc.
  6. Treat hazardous waste based on the approved IP

Paper recycling and waste treatment

      

OVERVIEW OF GENERATED WASTE:

HAZARDOUS WASTE:

cat. number name of waste
12 01 18 Metal sludge
13 01 10 Non-chlorinated hydraulic mineral oils
13 02 05 Chlorine-free mineral motor or transmission oils
13 05 02 Oil separator sludge
13 05 03 Waste from dirt traps
13 08 02 Other emulsions (compressor oil)
15 01 02 Contaminated plastic packaging
15 01 04 Contaminated metallic packaging
15 02 02 Absorption agents, filtration materials,…

OTHER WASTES:

cat. number name of waste
03 03 07 Mechanically separated pulp excretion
03 03 10 Excretion fibres, mechanical separation sludge, …
03 03 11 Wastewater purification sludge...
15 01 02 Plastic packaging
17 04 05 Iron and steel
17 04 11 Cables
20 03 01 Mixed municipal waste
 

 

TAKE-BACK OF SELECTED PRODUCTS:

Used devices (refrigerators, microwaves, electric kettles, computers, monitors, light tubes, small appliances,...) – are considered waste, used devices are to be handed in via take-back.

 

TRANSPORT:

Repairs carried out at service shops or by an expert company on the premises of the company – filters, used oils, car batteries, etc. – are taken away by the company – there is no waste created for the purposes of CEREPA, a.s.

 

WASTE OF OTHER ORIGIN:

The company is not a facility specifically designated for waste treatment according to § 14, sec. 1 of Act No. 185/2001 Coll. on Waste, as amended. It is a facility according to § 14, sec. of Act No. 185/2001 Coll. on Waste, as amended. In accordance with this establishment of the Waste Act, the company only utilizes wastes that satisfy conditions for inbound raw materials, i.e., various categories of waste paper – paper and pasteboard, paper and pasteboard packages, paper sorting waste and pasteboard intended for recycling (e.g., waste catalogue numbers 200101, 150101, 191201, 030308,…). When treating such waste, care must be taken not to violate special legal regulations applied to the usage of the facility, or hygiene and environmental regulations. Operation of this facility does not require the approval to operate a facility used for waste treatment, collection or buy-out.

PRODUCTION OF WASTE:

cat. number
of waste
name
of waste
category
of waste
amount
approx. t/year
030307 Mechanical paper pulping excretion O 300
030310 Excretion fibres from paper sorting O 350
030311 Wastewater purification sludge O 7 200
120118 Metal sludge N 0,8
130110 Chlorine-free hydraulic mineral oils N 0,4
130205 Chlorine-free mineral transmission oils N 0,4
130502 Oil separator sludge N 0,3
130503 Sludge from impurity latchers N 0,3
130802 Other emulsions (compressor oil) N 0,1
150102 Plastic packages O 4
150102 Polluted plastic packages N 0,25
150104 Polluted metal packages N 0.04
150202 Absorption agents N 0,15
160204 Discarded cables O 0,05
170405 Iron and steel O 7,5
200301 Communal waste O 15

 

WASTE COLLECTION AND STORAGE

At CEREPA, a.s., there are no places designated for waste storage. The waste is collected within properly labelled gathering areas. For hazardous waste, the gathering areas are supplemented with identification labels and graphic symbols describing hazardous properties according to the related legal obligations as amended.

The collection vessels are positioned by individual operations. The workers of the company place individual types of waste into collection vessels labelled with the appropriate lettering for the stored waste.

After filling the vessels, the waste is handed over to expert companies for utilization or disposal.

Description of individual waste gathering areas:

030307 - Paper pulping excretion -    O

 The pulping excretion gathering area is located close to the origin of the waste (the fibreglass hall) – it consists of a reinforced panel surface and side panels; can hold approx. 30 t of waste.

030310 – Excretion fibres from paper sorting -   O

The Excretion fibres gathering area is located by the fibreglass hall – it consists of a reinforced panel surface and side panels; can hold approx. 30 t of waste.

030311 – Stationery wastewater purification sludge -   O 

The stationery wastewater purification sludge gathering area is located by the fibreglass hall – reinforced surface with side panels for approx. 400 t of waste.

120118 – Metal sludge -   N

An impermeable container next to the origin of the waste in the basement of the PS5 machine, can hold approx. 1 t of waste. The container is labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

130110 – Chlorine-free hydraulic oil -   N

200l steel barrels above the collection reservoir locked in the oil warehouse. The barrels are labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

130205 – Chlorine-free engine/transmission oil -  N

200l steel barrels above the collection reservoir locked in the oil warehouse. The barrels are labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

130802 – Compressor oil -  N

1000l plastic container next to the origin of the waste in the basement of the PS5 machine. The container is labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

 130502 - Oil separator sludge -  N

An impermeable reservoir directly adjacent to the oil-heavy water purification equipment – labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel

130503 – Sludge from impurity latchers -  N

An impermeable reservoir directly adjacent to the oil-heavy water purification equipment – labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel

 150102 -  Plastic packages -  O

Plastic bags in steel holders positioned by individual workplaces. When filled, they are placed in the container stationed in front of the steel warehouse at the gatehouse.

150102 – Polluted plastic packages -  N

Plastic bags in plastic bins by specific workplaces (workshop, stationery machine,...). When filled, they are placed in the container stationed within the hazardous waste gathering area at the gatehouse – labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

150104 – Polluted metal packages -  N

Plastic bags in plastic bins by specific workplaces (workshop, stationery machine,...). When filled, they are placed in the container stationed within the hazardous waste gathering area at the gatehouse – labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

150202 – Absorption agents (polluted paper)-  N

Plastic bags in plastic bins by specific workplaces (workshop, stationery machine,...). When filled, they are placed in the container stationed within the hazardous waste gathering area at the gatehouse – labelled with the name of the waste, graphic hazard symbol, waste ID and name of the responsible personnel.

160204 – Discarded cables -  O

A metal container under the roof within the electro workshop area

170405 – Iron and steel -  O

An iron-based metal gathering area adjacent to the fibreglass hall, consists of a reinforced surface with side panels + 3 open containers on the panel surface near the workshop.

200301 – Communal waste -  O

Bins are positioned around the premises of the company.

WASTE UTILIZATION AND DISPOSAL

CEREPA, a.s. uses waste for its own production – paper and pasteboard as an inbound raw material for the production of hygienic materials. The waste is purchased from various distributors, along with use of internally by-produced excretions from the stationery machine and the processing machines.

The waste produced within the company is handed over to authorized external companies for utilization or disposal. The activity is ensured via order forms or directly via a contract-based relationship. The individual documents are stored by the environment manager of the company.

Based on the nature and volume of the production, it cannot be expected to significantly approximate the waste generation. The emphasis in put on material utilization.

Of the total amount of waste, most of it is handed over for further processing. Most of the waste consists of paper mill sludge, which is handed over to brickyards as an inbound material for brick production.

Description of treatment of individual waste types:

030307 Mechanical paper pulping excretion junkyard SOMPO Pelhřimov
030310 Excretion fibres from paper sorting re-cultivation OK PROJEKT s.r.o. České Budějovice
030311 Wastewater purification sludge inbound material for brickyards HELUZ Dolní Bukovsko
120118 Metal sludge disposal EKO-PE s.r.o. Pelhřimov
130110 Chlorine-free hydraulic mineral oil disposal EKO-PE s.r.o. Pelhřimov
130205 Chlorine-free transmission mineral oil disposal EKO-PE s.r.o. Pelhřimov
130502 Oil separator sludge disposal EKO-PE s.r.o. Pelhřimov
130503 Impurity latcher sludge disposal disposal EKO-PE s.r.o. Pelhřimov
130802 Other emulsions (compressor oil) disposal EKO-PE s.r.o. Pelhřimov
150102 Plastic packages utilization MH - odpady s.r.o., Tábor
150102 Polluted plastic packages disposal EKO-PE s.r.o. Pelhřimov
150104 Polluted metal packages disposal EKO-PE s.r.o. Pelhřimov
150202 Absorption agents disposal EKO-PE s.r.o. Pelhřimov
160204 Discarded cables utilization EKO-PE s.r.o. Pelhřimov
170405 Iron and steel utilization EKOPRON  METALs.r.o. Nová Včelnice
200301 Communal waste junkyard SOMPO a.s. Pelhřimov