The provision for Environmental Audit (Statement) as prescribed under the Environmental Protection Act for 1986 has great promise but has not been able to deliver. It was designed to be a tool through which corporates analyze their environmental performance in time and take suitable measures for improvement in resource consumption and waste management. Being linked to regulations, it made industry apprehensive, apprehensive of the fact that non compliance could be used to their legal disadvantage by the regulator. This introduced some amount of misreporting in order to make the report acceptable to regulatory agencies rather than helping the industry to introspect and improve. Voluntary approaches therefore, delinked to regulation therefore are assumed to play a more important role. Public disclosures of performance indicators provide powerful financial, social and reputational incentives for reducing negative externalities. It can also induce improvements from bad performers (which may otherwise require costly litigation) and introduce a system where corporate internalize reputation effects and perform better. The PROPER PROKASIH, Indonesia’s public disclosure program has been very successful in awarding good performers and calling public attention to polluters who are not in compliance with the regulations. (Regulation in the Information age-Indonesian Public Information Program in www. performeks.com/media/downloads/information_regulation.pdf) Philippines, Colombia, Mexico and Brazil have also undertaken identical programmes.

Here at home the Centre for Science and Environment has attempted a green rating of the Paper, Automobile and Chloralkali sector (The Greenest Paper Mill in India, July, 18, 1999, cseindia.org; Who is India’s Worst Paper Maker, Down to Earth, October 15, 2004 and Environmental Rating of Indian Caustic Chlorine Sector, Chandra Bhushan and Sunita Narain, C.S.E.) and ranked the major players on environmental performance . Another study done by the same organization for the cement industry pointed out that where economic logic met environmental objectives, the industry did well like in energy use and utilization of wastes but where investments did not yield short terms results the industry failed to meet expectations like in mine management, emission control and regulating livelihoods. Societally the industry was found to be dismal. (Cement: Not As Bad As We Thought, Down to Earth, December 31, 2005). Most of these studies point out that the major factors wrong with these industries is an inefficient use of resources and a poor technology base. (The Greenest Paper Mill in India, July 18, 1999, cseindia.org/node/441)

A pilot programme for environmental performance rating and public disclosure for industries was also initiated as part of a World Bank Programme and implemented collectively through the C.I.I., World Bank and the Uttar Pradesh Pollution Control Board. Both the authors to the present study were part of the study initiated in May 2001 which was coordinated from the World Bank by Mr. Carter Brandon, Dr. Smita Misra, Dr. Sushmita Dasgupta. (Also covered in Dr. Yashpal Singh, Environmental Performance Rating of Distilleries.www.oecd.org/data oecd) The programme covered 33 industries of different sizes and sectors at Ghaziabad and Noida. Industries were classified as Black and Red (implying lack of compliance) and Blue, Green and Gold (different levels of achieving compliance). Out of the 33 participating industries 6 were rated as Gold and Green, 16 rated Blue and 11 rated Black. This was a location specific compliance rating programme including small and medium enterprise also. It was not designed to be an environmental performance rating.

The Charter on Corporate Responsibility for Environmental Protection,2003 introduced through the efforts of the MoEF, the Pollution Control Boards and Industry Associations has seen a major break through in voluntary environmental performance.

In spite of the immense advantages that voluntary disclosure systems have, environmental performance rating exercises have been attempted but at a few places in India.

A pilot programme was commissioned by the U.P. Pollution Control Board in 2000 to evaluate and rate the environmental performance of the units in the Alcohol Industry. (Y. Singh, 2004, Environmental Performance Rating of Distilleries.www.oecd.org/data oecd) The study involved identification of the environmental indicators associated with the various activities in Alcohol production, understanding their environmental impacts and rating the environmental performance for intra industry comparisons by working out appropriate weightage systems for these indicators. The highlight of the study was the analysis of resource utilization efficiency of the units and its impact on environmental performance as well as profitability. The results of the study along with the names of the top 5 and bottom five performers were presented in an ‘open house’ where representatives from most of the participating distilleries were present. The report had concluded that in the case of Uttar Pradesh, the environmental performance of distilleries in western and Central Uttar Pradesh is better. Semi urban distilleries have a better performance as compared to rural based ones. Remarkably the study also revealed that improved environmental performance leads to better profitability. The industry was however observed to   exhibit insensitiveness to the use of raw materials, water, fuel, and power which results in enormous cost escalations. It was estimated that the sector could save more than Rs 100 crores per year it only the bad performers could come to the level of the best performers. The recommendations of the study were circulated and discussed in another open house. The participating distilleries had assured that they would take necessary action and improve their environmental performance.

Dr. Pradeep Kumar the prime mover behind this programme had hoped that the study would lead to better control of industrial Pollution besides improving the efficiency of units. The report was also presented by Dr. Yashpal Singh before representatives from all over the world at an International Conference on Economic Instruments held at Paris in 2004.The World Bank recognized this report as an important study and published a poster acknowledging the utility of the study. The poster also recommended that the exercise should be repeated so as to assess benefits.

It is in this context that the Distillery sector has been revisited to evaluate the impacts of the previous study. It also intends to tell the industry where it can still improve in order to earn better profits and reputation. While the earlier study looked into the performance indicators for the years 1998-99 to 2000-2001, this study covered the year 2004-05 to 2006-07.

The present report presents a comparative study of both the assessments. The Distillery sector with an installed capacity to convert over 3 million tonnes of molasses annually in U.P. is one of the major industrial sectors with a constantly growing contribution to the state exchequer by way of excise duty (Rs. 2912.90 Crores in 2004-2005, Rs. 3114.3 Crores in 2005-2006 and Rs 3518.3 Crores in 2006-2007). It also provides employment to more than 10,000 persons in the state. The industry has grown considerably over years. While there were 37 operational distilleries in U.P. (35 molasses based and 2 broken grains and malt based) out of a total of 43 distilleries in 2000-2001, 59 distilleries have been reported for 2006-2007 (56 Molasses based and 3 grain based). All these distilleries were requested to participate in the study. Out of these, 36 distilleries   participated. 24 distilleries have participated in both the 2000-2001 and 2006-2007 evaluations.

Conclusions

The study for the period 2000-2001 had indicated the following:

1.         Distilleries in central and western U.P. are marginally better performers.

2.         The semi urban distilleries were observed to perform better than the urban and rural based units.

3.         57% distilleries are located in the Ganga catchment followed by Ghagra and Yamuna. 86% of the distilleries discharge their effluents into the rivers (Ghagra-5, Gomti-1, Ganga-18 and Yamuna-6)

4.         An improved environmental performance leads to better profitability.

5.         The sector is not sensitive to the efficient use of raw materials, water, fuel and power. Optimization in raw material consumption and judicious use of water and energy shall reduce the production cost and increase profitability. This will make the product more competitive in the Global market and help the industry to maximize the capacity utilization.

6.         If the bad performers evaluate the best performers, the sector is likely to save Rs. 105.81 Crores by optimizing resource utilization (Molasses Rs. 26.95 Crores, Water Rs. 12.04 Crores, Biogas Rs. 22.50 Crores, Total Energy Rs. 45.32 Crores)

The following recommendations were made and presented before an open house session with Industry representatives and the Pollution Control Board.

1.         Eighteen out of the 33 units studied have a very poor environmental performance.

2.         All plants should have facilities to monitor the amount of biogas generated. They must also ensure to utilize the gas in boilers to meet the energy requirements. Where the biogas generation is poor, industries should retrofit the inefficient plants.

3.         Those units which have not installed the second aerobic stage should do it at the earliest.

4.         There is immense scope for reducing water consumption. This should be implemented.

5.         Metering systems should be installed to monitor consumption of biogas, water and electricity.

6.         Wherever feasible effluents should be utilized in production of bio-manure or in the case of grain based distilleries as cattle feed. Use of treated effluents for irrigation should be encouraged.

7.         Energy audit and trainings should be utilized

8.         Best available technologies should be utilized.

9.         Distilleries should be encouraged to implement ISO 14001.

Against these findings and recommendations these has been a considerable improvement in environmental performance in 2006-2007. 24 distilleries were common to both the phases of the study, 22 of these have improved by way of total environmental performance, 12 in terms of capacity utilization, 18 in terms of molasses consumption, 17 in terms of average recovery of alcohol, 18 in terms of water consumption, 10 (out 0f 22) in terms of total energy consumption, 14 (out of 22) in terms of total renewable energy consumption, 17 (out of 22) in terms of spent wash generation, 13 (out of 19) in terms of biogas generation, 18 (out of 22) in terms of dilution ratio.(Tables 2 to 10.

The repeat study has also reiterated the findings of the earlier study that an improved environmental performance leads to better profitability. There has been a considerable improvement in per capita use of resources although there is still scope for improvement. Two industries have adopted technologies based on concentration of spent wash and burning the same in better to generate steam and power for the process. These units show improved performance on all the energy indicators and have no effluent issues. Some new units installed in 2006-2007 or later are based on this technology.

Download the full document here : Distillery_Rating_UP

1.         Spent wash to be utilized for compost making with press mud/Agriculture residue/Municipal wastes.

2.         Spent wash to be concentrated and dried/incinerated.

3.         Effluent to be used for irrigation only after Biomethanation, two stage secondary treatment and dilution with process water.

4.         Effluents (BOD<2500 mg/L) to be discharged in a controlled manner into the sea only after Biomethanation and secondary treatment so that D.O. does not fall below 4 mg/L in the mixing zone.

5.         To be used in fertiirrigation as one time controlled application on land after detailed study.

6.         Achieve zero effluents discharge in inland surface waters by December 2005.

It was also decided that new stand alone distilleries and expansions of existing distilleries will not be given environmental clearance unless they achieve zero effluent discharge in surface/ground water.

The AIDA has compiled data from 233 Distilleries across the country in 2006. Based on this data,101 distilleries had achieved 100% utilization of spent wash,17 gave incomplete information, 34 achieved 50 to 75% utilization and 22 distilleries were closed. (aidaindia.org/its08 and cpcb.nic.in).

Experimenting for safety,  samples of treated hospital waste and garden soil were injected with HIV-positive and Hepatitis B-positive blood and some salmonella cultures. The results revealed no trace of virus from the treated samples.

Over the years, 400 kg of manure has been taken from the from the clinic to the 22-acre farm where they grow over 15,000 fruit trees, mostly chickoo and mango.  Chemical fertilisers and insecticides would have cost around Rs 20,000 a year. Considerable savings indeed, and from a most unlikely source.

Agriculture scientists would like the farmers to realise that reduction of chemical based fertilizers and pesticides can benefit both man and earth over the long run, and in particular for farmers, as a major portion of whose money is spent on buying these chemicals.

Value of waste
The focus, they believe must shift to educating farmers on the value of waste matter being generated in both their fields and homes and the technology to convert these waste into wealth. Their farm economics will definitely improve if they realise and adopt this.

It is precisely on these lines that scientists at the Myrada Krishi Vigyan Kendra at Gobichettipalayam, in Erode, Tamil Nadu have been working for the past several years in implementing a project called IFD (Integrated farm development model). Also called as LESA (Low External Input Sustainable Agriculture) the project is at present operational in about 32 villages in Erode district of Tamil Nadu.
Innovative model

According to P. Alagesan, Programme Coordinator, IFD is an innovative model especially designed for small scale farmers in improving farm productivity in a sustainable manner through integrating farm resources by recycling farm and home wastes. “The main concept of IFD is to integrate the animal and human wastes into useful and productive components such as for the manufacture of vermicompost, pest repellants and biogas thereby reducing input cost for farmers,” he said.
Bio pest repellants

For example, in villages, the urine and dung from cattle is usually washed into a drain or the dung is collected, dried and used as cooking fuel.

“But our IFD farmers collect the urine and dung in a collection tank and use it for generating biogas and manufacturing biogrowth promoters such as Panchagavya and Amirtha karaisal, to make bio pest-repellants,” explained Mr. Alagesan.

The spent slurry from the bio gas plant is used to make high quality manure by adding other farm wastes to it, and can also be used to breed earth worms.

“To ensure food and fodder security our research team has been conducting several programmes to emphasize the importance of kitchen gardens. The size of the kitchen garden depends upon the family size and income (usually 2-5 cents). A limited supply of water channelled through a low cost micro irrigation system ensures a good harvest,” he said.

High yielding green fodder varieties are also grown in these gardens to provide fodder to the animals. By growing these fodder varieties, the cost of buying feed has come down to nearly 12 per cent, explained Mr. Alagesan.

Farmer friendly
Technology must be farmer friendly and IFD farmers have been trained on scientific storage of harvested produce. The farmers store their harvested grains in special grain structures called ‘pucca koti’ (Hindi word) and metal bins.

These storage structures have been able to minimize grain loss to nearly 20 per cent and also protect the harvested produce from pest and pathogenic infestations. Finally, the waste generated from the farmer’s family is also not wasted. A eco-san toilet has been designed to collect the faeces and urine separately.
Rich nutrient

The faeces is covered with wood ash after every use and it falls into a soil pit and decomposes into a rich nutrient which can be safely used as manure for the field.

The urine is separately channelled to the kitchen garden where it seeps through the earth to nourish the plants.

Studies conducted in these villages have shown that about 35 per cent of external input cost has been reduced by effective utilization of farm and home wastes.
Forest regeneration

Use of biogas (2 cubic metre capacity has the potential to save about 210 kg of fuel wood per month) brought down firewood consumption. In a village called M.P. Doddi about nine tonnes of fuel wood in a month has been saved which has a direct impact on regeneration of forest area around the region.

Respiratory problems commonly encountered by the rural women in smokey kitchens have largely been minimized.

UNICEF has identified this as an innovative model and has planned to replicate it in other parts of the nation.

Gupta’s father started off in the late 1960s by supplying hair to exporters, then set up his own unit in Eluru in Andhra Pradesh a decade later. His company has since bagged export awards for 14 years.

Apart from barber cuttings and cut hair from temples( Tirupati temple alone sells a staggering Rs 20 crore worth annually), a large portion of it comes from households across India, collected by rag-pickers and garbage collectors, to Eluru.

Here it is sorted into lengths and colours, cleaned, washed and dried, and then shipped out in containers. Each month, 30-35 tonnes of hair is exported to 32 countries. China is the biggest buyer.

The students of National Model School in Peelamedu, G.R. Damodaran School on Avanashi Road and Elgi Matriculation Higher Secondary School in Vellalore have set up bio-compost pits on the school premises to decompose wastes into organic manure. Two baskets are kept at various points inside the campus – one for non-biodegradable wastes such as chocolate wrappers, pen caps and plastic bags and another for biodegradable wastes that include food leftovers, waste papers, dry leaves, dry flowers and twigs.

Coordinator of Siruthuli A.C. Prabhu says the process is simple. “With the help of students, a six ft length, four ft breadth and one ft deep pit is dug out and waste from trees inside the school campus and vegetable wastes are dumped into it and covered by a layer of soil. Water and diluted Effective Microbes (EM) solution are added and the contents are allowed to decay. After 45 days, the waste is decomposed into manure and used for the afforestation programme of the school,” he adds.

The students visit neighbouring areas to spread awareness on the need to have bio-compost pits. They  give a demonstration on the method to be followed beginning with segregation of waste at source.

The amount of soil available in potted plants is sufficient for a bio-compost pit. A litre of EM solution concentrate comes at Rs. 240 and is available at outlets selling agro-based products. It can be diluted with 100 litres of water and sprayed on the contents on alternate days.

Vermigold International, her company, is a Rs 25 lakh a year business that has graduated to large projects.She has launched a project jointly with the Municipal Corporation of Greater Mumbai (MCM) where MCM has leased her 2,400 sq.m of land for free, and has promised to provide 35 tonnes of vegetable and flower waste daily from the Dadar market. The unit cost Rs 10 lakh, and MCM gave an interest-free mobilisation advance of Rs 5 lakh (to be repaid in 10 instalments over 28 months, with an 18-month moratorium). The other Rs 5 lakh came from Saptarshi.

The unit has a monthly capacity of 100 tonnes; compost will be retailed at Rs 15 a kg. Saptarshi will pay MCM Rs 25,000 a month or 10 per cent of profits, whichever is higher.

At a small coastal Industrial zone Kalundborg near Copenhagan an exemplary material exchange is being practiced. The exchange involves a 1500M.W. Power plant,(Asuaes Power Station),a 3.2 million metric tones capacity oil refinery,(Stat Oil),a 14 million square meters of Gypsum Board manufacturing unit,(Gyproc),an Intermational Biotechnology company with a sales in excess of $2 Billion and the city of Kalundborg which supplies residential heat and hot water to the residents.
The Power plant supplies waste steam to the refinery and in turn gets refinery gas which substitutes some of the coal. Excess steam is also supplied to the Biotechnology Company, (Novo Nosdisk) and the city of Kalundborg for heating. This replaces almost 3500 individual furnaces which otherwise are a source of high air pollution. Desulphurization at the Power plant also produces Gypsum which meets1/3rd of the need of Gypsum in the Board manufacturing unit. Sludge from the Biotechnology Company is used as fertilizer on nearby farms and surplus yeast from its Insulin plant is sold to farmers as pig food.

From:
Damle Anand- Use of Fly Ash in Burnt Clay manufacturing, Cleaner Technology, Impacts/12/2003-2004, MOEF-CPCB, Govt. of India, 2003 pages11-21

Her organic business venture Daily Dump offers different types of composters that convert the waste generated in one’s  kitchen into compost. If the customers do not require the compost, it can be sold back to Daily Dump.

What began as a small venture with family members and potters, three years ago, Daily dump is set to treble its turnover to Rs 36,00,000 (Rs 3.6 million) this year. Today, the company has about 4,500 dedicated customers in Bangalore who use the profitable composters.

The response has been encouraging and the company has steadily grown over the past 3 years. In the first year, Daily Dump made a turnover of Rs 200,000, which increased to 12,00,000 (Rs 1.2 million) last year.

Poonam says home waste generated in one’s kitchen is 50-70 per cent organic, but urban India has still not found an effective way to dispose this waste, which can actually be churned back into the system by converting it into useful organic manure.

“Keeping this waste off the streets will be the biggest challenge that civic authorities across every city will face. If we can convert this into compost, it can reduce the mess on the streets by 60 per cent, that’s a big impact,” Poonam points out.

The Daily Dump design is available to anyone who is interested, the designs are protected by a creative commons license and the cloning approach allows anyone to use these designs. “I plan to support every person who is brave enough to clone this in every possible manner,” says Poonam.

Poonam Kasturi shares her experiences of  ‘a great ride, tough but very fulfilling’ of converting household waste into wealth and how her products can make a far reaching impact in a country like India.