Effluent and Emissions
To support working towards a cleaner world, Coats is implementing online, realtime monitoring of liquid waste effluent for sites discharging to the environment. It is investing in the construction of new or upgraded wastewater treatment plants at sites as well as recycling water where appropriate. It currently recycles 24% of process water.
Leader's Voice
“We have long taken a
precautionary approach to
the environment. This was
the reason we developed and
started to implement our own
global effluent standards in
2011, as we recognised that
simply complying with national
effluent standards was not
enough.
Since then legislative limits
around the world have been
progressively tightening and in
some locations have superseded
our global standards.
Complying with government
standards is always a given for
us, and continues to be a driver
of our investment plans, but
we still believe that wherever
we operate the environment is
equally precious and that we
must therefore apply global
standards to our operations.
For this reason we have now
adopted the Zero Discharge of
Hazardous Chemicals standards
as our global standards. This
allows us to continue to be a
leader within our industry and
to work to a set of commonly
accepted standards that did not
exist in the past.
A huge step forward has also
been the implementation of
online monitoring of effluent
to ensure that our treatment
plants are operating within
limits 100% of the time.”
Stuart Morgan
Chief Legal & Risk Officer and
Group Company Secretary
Effluent and Emissions Strategy
Our long term vision is to cease to use water for dyeing, but there is no technology currently available at industrial level to achieve that goal, so while we continue to use aqueous technology we will have a need to manage our effluent to avoid detrimental impacts on the environment. Since 2011 all of our units have worked to an internal set of effluent standards. These are, in most cases, considerably more stringent than the local requirements. In 2016 we joined the Zero Discharge of Hazardous Chemicals (ZDHC) association as this was gathering momentum across the textile industry with the goal of creating common standards that would be applicable across the whole industry. In 2019 we adopted the ZDHC standards as our standards instead of the Coats standards. Our target is to have all units meeting the ZDHC standards by 2022, and thanks to the work already done over 60% of our effluent was compliant by the end of 2019. Late in 2019 the ZDHC standard was updated to include sludge testing as well as effluent. During 2020 we will be adding sludge testing to our targets and adjusting plans accordingly. Early results indicate that we will have to undertake additional actions to achieve uniform sludge compliance. Ensuring that all of our units are capable of meeting the required limits is important but it is equally important to ensure that effluent treatment plants are working consistently and to ensure this we installed, during 2018, automated measurement systems in all of our key units. These take measurements of core parameters every 30 seconds and issue automated warnings if the systems begin to approach control units. We also piloted, in 2019, a system that automatically shuts off discharge if a standards breach is likely and will install this across other units in 2020.
As a significant user of energy, Green House Gas (GHG) emissions are a key concern for us. Our activities have been described above in the Energy section; reduction of energy usage and transition of energy sourcing to renewables. Our target, will be determined once we have established our renewable energy target in 2020. In 2019 we achieved a reduction of 3% in GHG emissions intensity and a reduction of 5% in absolute GHG emissions compared to 2018 (excluding NA Crafts from 2018 data and including Gotex and Patrick Yarns).
By 2022, we will build on our global standard by complying with the Zero Discharge of Hazardous Chemicals (ZDHC) effluent standards
Meeting Zero Discharge of Hazardous Chemicals Effluent Standards by 2022
Our aim is to progressively
reduce the use of chemicals
in our processes. The very
comprehensive Coats Restricted
Substances List system that
we have had in place now
for 15 years and which at
least aligns with the tightest
requirements from any of
our customers has been
instrumental in ensuring that
we have reduced or eliminated
hazardous chemicals from our
operations.
The Zero Discharge
of Hazardous Chemicals
system is a very welcome next
step as it will drive improved
chemical management across
the supply chain, and we are
delighted to be participants in
the programme. Our approach
essentially rests on three
pillars; tight control of input
chemicals, appropriate design
of effluent treatment plants
and continuous automated
monitoring so that we can be
confident that our effluent
treatment plants are always
functioning optimally.
Maintaining high standards through a
continuous approach
Our long-term vision is to stop using
water for dyeing. But there is currently no
technology available at industrial level to
achieve that goal. So, while we continue
to use aqueous technology, our diligent
and continuous approach helps to avoid
any negative impacts on the environment
from our wastewater.
Of the water used in 2019, 62% was
discharged as waste effluent (down
9% from 2018). Any effluent that we
discharge needs to comply with local
legislation and discharge limits and meet
our internal global effluent policy, which
now incorporates ZDHC standards (see
below). This policy has been developed to
ensure that all our operations, regardless
of location, will meet a high standard
in terms of the effluent they discharge.
During 2019 we have established an
online and dynamic register of legislative
changes in all the countries that we
operate in which includes control of
operational permits, incident reporting
and control of improvement projects.
To improve monitoring of our wastewater
discharges and ensure continuous
compliance, new sensors have been
installed in the final discharge point of
12 sites, including all sites where treated
wastewater is released directly into the
environment, giving immediate feedback
on parameters that would normally
take up to five days to test in laboratory.
These sensors monitor the quality of
effluent discharges every 30 seconds
measuring against five criteria, including
temperature, pH, biological oxygen
demand, chemical oxygen demand and
total suspended solids. The data is sent to
a ‘real-time’ dashboard and if the levels
of any of the parameters gets close to or
exceed a limit, the operational team will
be notified immediately. This enables us
to respond rapidly to mitigate any issues
and provides the detailed information we
need to investigate the root cause of the
issue, remedy the situation and ensure no
future incidences take place.
During 2019 we also ran a successful pilot in Shenzhen
whereby, if target parameters for online
tests are in danger of breach, the
discharge valve is closed and the treated
effluent is routed back to the start of the
treatment process. This process will be
implemented in other units during 2020.
As an unexpected benefit, the new
sensors also allowed us to see spikes in
suspended solids when the power supply
was re-established after a power cut.
Recognising this trend enabled us make
some key adjustments to stop those spikes
from happening at the start up. In 2020,
additional sensors will be employed,
including a new conductivity probe in
Chittagong in Bangladesh.
Over the past five years, we have spent
over $13 million on new effluent treatment
plants and related technology and this
spend will continue. During 2019, two new
wastewater treatment plants came into
service in Honduras and in Mexico.
Zero Discharge of Hazardous
Chemicals (ZDHC)
In 2016, we signed up to the Zero
Discharge of Hazardous Chemical (ZDHC)
programme, which aims to unify efforts
to eliminate hazardous chemicals from
the global footwear and textile supply
chain. Launched by six leading brands,
the ZDHC programme has since grown
to 30 signatory brands, 114 value chain
affiliates and 21 associates. Coats is a
value-chain affiliate.
In 2019, we adopted the ZDHC
conventional parameters with foundational
limits as our Coats internal standards across
all our direct discharge sites. This applies
to all sites, including those that are not
part of the apparel and footwear supply
chain. We aim to have all units meeting
the ZDHC standards by 2022.
As of the end of 2019, over 60% of our effluent was
compliant with ZDHC standards, putting
us on track to meet our target. The ZDHC
standards have been extended to include
sludge analysis and we will be assessing
this change and addressing compliance for
sludge during 2020.
Zero Liquid Discharge at
Ambasamudram
In 2019, we completed the implementation of a very significant Zero
Liquid Discharge (ZLD) system at our largest site in India at Ambasamudram,
Tamil Nadu.
This site consumes approximately 3,500 tonnes of water per day, which
previously was treated and discharged into the environment. To achieve zero
liquid discharge, the existing wastewater treatment plant was modified to
incorporate new cutting-edge technology, including ultrafiltration, reverse
osmosis and multi-effect evaporators. As a result around 95% of the water
entering the treatment plant is returned for reuse in the factory and the
remaining 5% is evaporated to leave a solid waste, which is used as a
cement additive by a local cement company. The steam required for the
new evaporators is generated using biomass, ensuring carbon neutrality
for this process.
In February 2019, we successfully closed down our treated wastewater
discharge channel in a ceremony witnessed by the Tamil Nadu Pollution
Control Board.
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