1. Solutions Forum II
Clean Technologies for
Green Industry
UNIDO
TEST Methodology
Carolina Gonzalez
29 October 2013
Nairobi, Kenya

2. Outline
1.
TEST Methodology
2.
Case studies & Results - MED TEST project
3.
Replication & Up-scaling

3. Green Industries
Green Industries means economies that strive for a more
sustainable pathway of growth, by undertaking green public
investments and implementing public policy initiatives that
encourage environmentally responsible private investments.
Decoupling resource depletion from
economic growth
www.unido.org/greenindustry

4. Transfer of Environmentally Sound
Technologies - TEST Methodology
Objective: Support sound management of resources use at
priority industrial hot spots, to minimize use of resources and
maximize productivity through the demonstration of best practices,
application of clean technologies, and capacity building.
The methodology demonstrates that
industries can achieve economic benefits
through the application of best
environmental practices and resource
efficiency.

5. TEST Global Application

6. Context
 The TEST integrated approach was developed by UNIDO in 2000,
it was implemented in 5 countries in the Danube River Basin.
 The TEST methodology aims to improve environmental
management and competitiveness of companies (primarily SMEs) in
developing countries and economies in transition.
 TEST consists of five management tools aimed at changing
practices in industries/companies in a comprehensive way in order to
ensure the adoption of environmental practices.

7. The 5 Tools of TEST
Resource Efficiency and Cleaner Production (RECP)
Environmental Management Systems (EMS)
Environmental Management Accounting (EMA)
Environmentally Sound Technologies (EST)
Corporate Social Responsibility (CSR)

8. TEST: major steps
Initial Review
Phase 1 RECP, EMS, EMA
Potential for improvement
Viability and commitment
EMA – total costs of material losses
RECP – BAT/BEPs
EMS – system support
Phase 2 EST
Phase 3 SES/CSR
Investment needing measures
Feasibility study, Financing
Evaluation and reflection
Sustainable Enterprise Strategy

9. Fundamentals of TEST programme
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Integrated approach that links sustainability to core business
strategy, management systems and manufacturing processes
Benchmarking company performance with ratios/technology
in the global market
Training, Monitoring, Follow up & Top management
engagement
Multidisciplinary skills and Technical sectoral expertise
Flexible approach depending on company size and baseline,
applicable at existing sites and for start-ups
Linking to existing financing investment schemes (SMEs)

10. MED – TEST Project
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Overall Objective: Build national capacities in UNIDO-TEST
integrated approach and conduct pilot projects within priority
industrial areas affecting the Mediterranean basin to
demonstrate the economical/environmental benefits of resource
efficiency and sustainable production.
Countries: Tunisia, Morocco and Egypt
Funding: 2.1 M USD - GEF, Italian Government
Coverage: 43 industries, 7 industrial sectors
Duration: 2009-2012
www.unido.org/medtest

11. Selection of companies
Company participation is voluntary
Industry motivation to join TEST: productivity and
cost reduction, pressure from supply chain and
customers, regulatory compliance
Cash Co-financing from companies required
(ownership)
Selection criteria:
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Management commitment
Environmental problems &
potential for improvement

Financial viability - creditworthiness


12. Components & outputs
Components
Capacity Building
Pilot Demonstrations
Dissemination & Replication
Outputs
Network of national resources, institutions
and service providers trained and
experienced in implementing TEST
integrated approach in industry.
• Best practices introduced with economic
benefits
• Reduction of pollution discharges
• Investment portfolio for cleaner technology
transfer tapping existing national financial
instruments
• National and Regional dissemination of
best practices and lessons learned
• National replication roadmaps and kick off
of commercially based TEST application in
new companies

13. Priority Sectors



Tunisia: Agro-food, Textile, Leather
Morocco: Agro-food, textile, Metal, Ceramic
Egypt: Agro-food, Chemical, Pulp & paper
Ceramic; 2
Textile; 8
Food &
Beverage; 16
Metal; 3
Chemical; 6
Pulp &
Paper; 4
Leather; 4

14. RECP: Types of measures


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Water conservation: cleaning techniques, in
process recycling and second grade applications
(water treatment units); monitoring & use of meters
Product recovery & valorisation: product push
before CIP, in process recycling, off specs &
returns from clients, packaging, valorisation of byproducts
Steam generation and distribution: insulation,
fuel switch, process integration
Electric system: power factor, compressors,
optimisation and heat recovery of chillers, cold
storage rooms, lighting

15. Project’s achievements in industries
Return on investment of identified measures
Number of m easures implemented, retained for study,
discarded
23%
Discarded
54%
Retained for study
23%
Implemented
0
100
200
300
400
500
600
700
0<PBP<0.5 yr
0.5<PBP<1.5 yr
1.5 yr<PBP<4 yr

16. MED TEST
Case Studies & Results

17. Company Cap-Bon (SCAPCB)
Case study: Food Sector
SCAPCB produces canned food. It has a daily production capacity to process
1,200 tons of fresh tomatoes.
Measures identified:
• Company designs: modification of the nozzle used for pre-rinsing and final
rinsing of fresh tomatoes, reduced the overall water consumption by 40%. It
also improved the overall quality of finished products.
• Valorization of by-products: waste from tomato
refinement sold to farmers to enrich animal fodder
• New equipment: installation of a water tank (300
m3) allowed for a more efficient distribution and use
of well water and protects submerged pumps
against water currents.
 Overall water savings of 129,737 m3/yr.

18. Société Moderne des Cuirs et Peaux (SMCP)
Case study: Leather Sector
SMCP is a leather company founded in 1965. Production is distributed in ovine
skins (57%, 525 tons/year), goat skins (10%, 90 tons/year) and bovine skins (33%,
300 tons/year). It produces for both local and international markets.
Measures identified:
• Reuse of chemicals: recovering chromium sulphate after
precipitation and filtering can replace 46% of the new
chromium with no impact on the quality of finished leather.
This allows for the reuse 24 tons/yr of recovered chromium
otherwise discharged as sludge
• New equipment: A change to perforated shaking drums facilitated the elimination
of salt from the salted hides. This resulted in the elimination of 120 tons/yr of salt
and a 40% reduction of chlorides in the wastewater.

19. GARTEX
Case study: Textile Sector
GARTEX is a jeans production and bleaching company fully focused
on exports, with a working capacity of 2,800,000 items/yr.
Measures identified:
• Adaptation of equipment: their washing machines were equipped
with double water exits, which facilitates the implementation of a
system for reuse of rinse water. By installing a network of gutters,
pipes and water pumps 11,250 m3 water can be saved annually.
• Change in programming: An automated programming was put in place which
establishes general washing and drying programmes, as well as subprogrammes to facilitate adjustments, thereby eliminating manual interference
and reducing error risk.
The change reduced water consumption by 25% (3.500 m3/yr), thermal energy
(162 MWh/year) and chemical products (6%).

20. Results: Egypt
Company
Size
(*)
Investments
[USD/yr]
Savings
[USD/yr]
Water
Savings
[%]
Energy
Savings
[%]
660
200
257,518
75,540
889,000
414,956
32
50
3
6
1,130
1,000
136,474
1,564,086
1,696,132
1,264,042
40
85
44
19
2,300
740
700
3,300
430
429,627
49,033
97,050
1,536,667
100,934
127,803
416,057
466,793
530,638
457,371
18
26
17
4
20
1
7
10
35
8
40
416,850
97,377
30
47
1,125
940
920
2,443,446
279,217
1,731,170
1,518,446
304,786
1,228,167
15
33
52
10
15
12
9,117,614
9,407,568
Food & Beverage Sector
Edfina Company for Preserved Food
Egyptian British Company for Development
(Galina-Agrofreeze)
Egyptian Company for Starch, Yeast & Detergents
El-Nile Soft Drinks Company (Crush)
Chemicals, Petrochemicals and petroleum sector
Extracted Oils and Derivatives Company
Misr Chemicals Company (MCI)
Solvay Alexandria Sodium Carbonate
Egyptian Petrochemicals Company (EPC)
Misr Petroleum Company (Lube Oil Blending Plant)
Leather sector, tanneries
Atef El Sayed Tannery
Pulp and paper sector
General Company for Paper Industry (RAKTA)
Moharrem Press Company
National Paper Company (NPC)
TOTAL

21. Results Morocco
Size (*)
Investments
[USD/yr]
Savings
[USD/yr]
Water
Savings [%]
Energy
Savings [%]
500
600
320
350
320
280,328
117,929
131,099
120,175
79,125
333,830
381,436
168,148
73,970
133,500
20
23
10
22
48
7
13
20
65
26
400
300
324,327
250,911
242,041
474,615
4
2
7
27
200
90
262,164
85,800
370,431
327,375
7
1
11
12
200
50
Company
347,538
87,125
2,086,566
433,180
205,306
3,143,814
80
80
4
12
Food Sector
Fromagerie BEL (dairy)
Colainord (dairy)
Cumarex (fish)
C2M (fish)
BOA (meat)
Textile Sector, finishing
Ecolorentel
Lavesma
Metal Sector
Aluminium du Maroc
Industube
Ceramic Sector
Ghorghiz
Ceramica Dersa
TOTAL

22. Results Tunisia
Size
(*)
Company
Investments
[USD/yr]
Savings
[USD/yr]
Water
Savings
[%]
Energy
Savings
[%]
493
50-250
308
119
202
547
191,200
98,139
827,410
56,331
29,200
484,945
133,700
73,639
746,638
75,454
194,600
546,903
12%
44%
16%
22%
12%
13%
17%
9%
13%
21%
14%
19%
55
185
150
60
80
40
76,500
181,800
139,000
37,500
1,264,645
76,200
55,600
111,836
91,300
28,800
491,860
67,200
10%
19%
24%
30%
56%
19%
30%
39%
7%
14%
10%
15%
180
35
50
523,000
287,000
184,000
446,800
97,200
125,000
14%
22%
8%
15%
3%
70%
Food & beverage Sector
Générale Industrielle Alimentaires Slama (GIAS)
Société de Conserves Alimentaires du Cap Bon
Tunisie Lait
Société de Boissons du Cap-Bon (SBC)
Societè Nouvelle de boisons
Centrale Latiere du Cap nord (CLC)
Textile Sector, finishing
Teinturerie et Finissage Mediterraneenne (TFM)
Gartex
Megastone
Traitex
Garment Dyeing Service
Star Wash
Leather Sector, tanneries
Tanneries Megisserie du Maghreb (TMM)
Société Moderne des Cuirs et Peaux (SMCP)
Tannerie du Nord Utique
TOTAL
4,456,870
3,286,530

23. MED TEST - Achievements
Key figures
6 National partners/service providers
30 TEST Trainees
43 Demonstration industries
958 Man days of training delivered to industry and trainees
Results Industry Demonstrations:
16 Millions USD/yr economic savings
9,600,000 m3/yr water savings
250,000 MWh/yr energy savings
Donor funds, 2.1 M USD, leveraged 20 M USD of private sector investment

24. Replication & Up-scaling
SWITCH-Med Demonstration and Networking
Components
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Funding: 17 M EUR, from the European Commission
Partners: UNIDO, CPRAC, UNEP-MAP & UNEP-DTIE
Countries (9): Morocco, Tunisia, Egypt, Lebanon,
Palestine, Jordan, Israel, Algeria and Libya.
Duration: 4 years (2014-2018)

25. SWITCH-Med
The objective of the SWITCH-Med is to facilitate the shift toward
Sustainable Consumption and Production (SCP) in the Southern
Mediterranean Region.
The SWITCH-Med umbrella programme consists of 3 Components:
Policy, Demonstration and Networking.
Demonstration Component:
 Sustainable production - MED TEST II
 Green entrepreneurship and civil society empowerment
 SCP Nation Action Plans demo
Networking Component
Facilitate networking & knowledge sharing among partners, and
foster lessons learned

26. THANK YOU
Carolina Gonzalez
Environmental Management Branch
Water Management Unit
C.Gonzalez-Castro@unido.org