Professional Documents
Culture Documents
FOR
Z – TANNERY
Plot 42/43 CHALLAWA INDUSTRIAL ESTATE, KANO
Prepared by
Prepra Nig.Ltd
31/32 BELLO ROAD, KANO
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Email: prepra@live.com
AUDIT PREPARERS
ABASS ZEIN
Chairman/CEO Z Tannery
ABDULMUNNIR KHAN
General Manager, Z Tannery
LIST OF FIGURES
LIST OF PLATES
LIST OF TABLES
TABLE OF CONTENT
Title Page i
List of Prepares ii
List of figures and Plate iii
List of Tables iv
Table of contents v – ix
Acknowledgement x
Exclusive Summery xi
ACKNOWLEDGEMENT
and staff of Z Tannery limited. In particular, the support and disposition of the
General Manager, Mr. Khan has been invaluable to the success of this report.
Prepra Nigeria ltd wishes to stress that in line with its policy, all information
obtained in the course of this Audi exercise as well as those contained in this
EXECUTIVE SUMMARY
This environmental audit (EA) was carried based on the guidelines and
regulation of the National Environmental Standards and Regulations
Enforcement Agency (NESREA) in particular Section 8 (k) of the Act that
empowers the Agency to make Regulations, one of which is the Regulations S. I
No 29, that requires existing industries to undertake environmental audit and
submit reports of such every three (3) years.
Desirous of complying with extant environmental laws and regulations Z Tannery
limited appointed MESSR PREPRA NIGERIA LTD – a NESREA accredited consultant
to conduct the audit.
In order to evaluate the impact of the activities of Z Tannery, an assessment of
the location in terms of compatibility and of the processes and housekeeping of
the factory was undertaken. This initial contact ensured management consent
and selection of audit team from the company.
Standard questionnaire was administered to the management and key staff to
obtain information that was used in the facility inspection as well as examination
of records and documents of the company.
The main activity in Z Tannery limited is tanning of hides and skins which involves
considerable use of water, either to cleanse them or in the form of process
liquors during the various unit processes. Generally, a tannery can contribute to
problems of health hazard by (i) causing depleting of oxygen in water where it is
discharged, thereby removing the dissolved oxygen required by fish and other
aquatic organisms for respiration, (ii) leading to high concentration of salts and
possible formation of metal sulphides which are very harmful to both human
beings and animal (iii) causing bacteriological pollution by pathogenic
organism.
This Audit exercise indicated that the operation of Z Tannery will result in short
and long term adverse impact to the environment as well as nuisance to the
community especially from waste water which is by far the most dominant
waste product. Thus various strategies for treating the wastewater have been
proffered as well as to minimize the generation instead of treatment. Further
measures in which the wastewater can be reused directly subject to the
guidelines of NESREA have also been suggested. In addition, suggestions were
made in the report that will ensure that resources are used appropriately and
efficiently.
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1.1 BACKGROUND
One of the efforts that have been made towards environmental protection in the
(UNCED) referred to as the Earth Summit and whose outcome is the Agenda 21,
Nigeria comply with environmental laws that protect the environment and
reports every three (3) years. In addition several other regulations in the NESREA
The NESREA Act, Section 7 (a) that vests in the Agency the responsibility to
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environmental matters
policies
Ensuring compliance, not only with laws, regulations and standards, but
also with company policies and the requirements of the NESREA endorsed
responses planned.
For the purpose of the mandatory Compliance Audit due every three (3) years,
from:
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NESREA Act No 25 of 2007 and those that will come into force from time to
time
The Audit criteria considered in this study included but not limited to:
legislations
Standards, rules, orders, etc made under an act and having the force of
law
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Pre – audit
On – site audit
Post – audit
management of Z Tannery.
i) Management commitment
audit was duly signed by the CEO. This signaled the commencement of the
audit.
The audit team was carefully selected and includes employees of Z Tunney and
Prepra Nigeria. The team leader is the NESREA accredited consultant while the
other team members have skills and knowledge relevant to the audit process.
Each member of the team was assigned his/her role and responsibilities and pre-
audit training was done to ensure that all the team members are adequately
members:
Federal and State database relevant to Z Tannery , such as, any nearby
hazardous waste sites; Industrial landfill; Solid waste sites, Drinking water
sources etc.
The objective of the on-site audit exercise is to determine whether audit criteria
are being complied with through the use of well-defined and systematic check
Outline procedures
Outline schedules
checklist
This exercise was conducted to investigate the presence of sensitive sites within
data collected such as, the nature of the past and present usage of the factory;
nature and operations in adjourning properties - type and use past and present;
above ground storage tanks ; Air sources mobile and stationary; Presence of
collected from effluent pit every day, over a period of seven days in suitable
(BOD) sulphide were collected separately in two glass bottles stoppers. The
dissolved oxygen and sulphide were fixed on the spot by the addition of winker
Air samples from factory floor, utility area, generator/boiler/workshop area and
main yard of the Z factory were collected as ambient with the aid of GILLIAN
BDX II abatement multi air flow sampler. Air was drawn into the cassette of the
sampler which already had a pre-weighted filter. After a period of 2hrs, the pre-
weighted filter was removed and re-weighed. The particulate level was then
calculated by dividing the difference in weight by the flow rate and time spent
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sampling.
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Relevant pollution indicator gases were sampled with the aid of CASELLA MX 21
Noise level measurement was taken in the three identified areas of Z factory
The wastewater was evaluated based on the criteria and NESREA guidelines, on
determined as follows:
The temperature and pH of the samples were determined on the spot; the
The methods for the determination of solid used is that of Hanson (Hanson,1973).
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The term’ Total ash’ is a measure of the total mineral content and was
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and total nitrogen were carried out using the argentimetric and ‘kjeldahl’
methods respectively. The amount of BOD was determined using the dilution
method. Estimation of metals was carried out by using perkin-Elmer Model 306
The mass balance approach was used in this study whereby, each process was
clearly demarcated in terms of inputs and outputs. This was achieved on the
simple principle that the total mass of material going into the process should
equal the total mass going out i.e. Input – losses = outputs
In Z Tannery, for example, the inputs considered were : raw materials – skins and
defenders) and utilities or services servicing each process (e.g water. energy,
steam, cooling water and compressed air). The losses from the inputs were also
The outputs are the final product(s). The mass of inputs to the process in Z
Tannery should balance the mass of outputs as products, emissions and wastes,
The following steps were followed to assess the input – output of Z Tannery.
Tannery.
comments
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Z-Tannery
The information gathered and data collected together with the overall findings
of this Audit report will be reviewed in line with the extant regulations with the
compliance.
The audit was conducted between, 25th October to 15th November 2014
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Manpower: Skilled 34
Semi-skilled 120
Unskilled 150
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The location of the Industrial estate within Kano metropolis is shown in Figure 1.
The factory is sited between latitude 110.53` 146 and longitude 0080.29`481.Based
extracted from Google earth. The site of the land in which the factory is located
All structures on the premises shown in Figure 2 have been approved by Kano
via a double leaf vehicular metal gate. The un – built portion of the premises
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remains in its natural topsoil save the immediate premises of the administrative
block which is paved with interlocking stone and landscaped with carpet grass.
The factory site is very firm, relatively level and well drained. Z tannery is very
close to Fata Tanning Co ltd, Ayafa Tannery, Fan Milk and United Gases. Access
to the factory is very easy because as seen in figure 3, the factory is located
about 450 meters off- the main Challawa Industrial estate road via the Industrial
link road. The factory is sited within an area demarcated for medium to
heavy wet industrial operation. There are three main warehouses that
make up 90% of the factory buildings. The main offices are situated near
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the entrance and are separate from the factory buildings. The whole
that report to the General Manager for day to day guidance. The
direction.
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M.D
G.M
Stores
Workshop Beam Wages
house
more durable and less susceptible to decomposition. A tannery is the term for a
place where the skins of animals are processed. It can be performed with either
Animal skins
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Chemicals
a) Sodium chloride
b) Sodium sulphide
c) Chrome
d) Sulfuric Acid
e) Ammonium sulphate
f) Caustic soda
g) Soda Ash
h) Ammonium liquor
i) Dyes
j) Bactericides
k) Fungicides
l) Formic Acid
m) Enzymes
n) Syntans
o) Synthetic oils
p) Vegetable oils
q) Lacquers
r) Pigments
The first stage of the leather production begins with the collection and sorting of
warehouse. Plate 2 shows sorted raw sheep skins in the company’s warehouse
2.5.2.1Curing
Preparing the skins begins by curing them with salt. Thus the skins form the
bacterial growth during the time lag that might occur from procuring the skins to
when it is processed. Curing removes excess water from the skins using a
wet- salting, skins are heavily salted, then pressed into packs for about 30 days.
In brine-curing, the skins are agitated in a salt water bath for about 16 hours.
Curing can also be done by preserving the skins at a very low temperature. In
The steps in the production of leather between curing and tanning are
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2.5.2.3 Soaking
In the process known as soaking, the hides are soaked in clean water to remove
the salt left over from curing and increase the moisture so that the hide or skin
2.5.2.4 Liming
After soaking, the hides and skins are taken for liming which is a treatment that
involves the addition of sharpening agents like sodium sulfide, cyanides, amines
tannage.
The weakening of the hair on the breakdown of the disulfide link of the amino
acid is called cystine, which is the characteristic of the ketarin class of protein
that gives strength to hair and wools (ketarin makes up 90% of the dry weight
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hair). The hydrogen atoms supplied by the sharpening agent weaken the
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The pH of the collagen is brought down to a lower level so that enzymes may
act on it in a process called de-liming. Depending on the end use of the leather,
skins may be treated with enzymes to soften them, a process called bating.
2.5.2.6 Pickling
Once bating is completed, the hides and skins are treated with a mixture of
common table salt and sulfuric acid, in a case a mineral tanning is to be done.
the penetration of mineral tanning agent into the substance. This process is
called picking. The common salt penetrates the skins twice as fast as the acid
and checks the ill effect of sudden drop of pH. The pH is very acidic when the
enough to fit between the fibers and residues of the collagen. Once the desired
is raised again to facilitate the process. This step is known as Basification. In the
raw state chrome tanned skins are blue in appearance and are therefore
referred to as Wet Blue. Chemicals used in tanning include chrome, salts, sulfuric
2.5.2.7 Retanning
The wet blue is selected and shaved to specified thickness often determined by
the final product to be used and subsequently moved back to the drum for re-
tanning. Re-tanning is the process of using oils and vegetable extract to convert
the requirement. The crust is now complete leather and can be finished to
various formats by the spray of pigments and lacquers. Chemicals used in re-
tanning includes, dyes, formic and sulfuric acids, fatliqours and Syntans
For finishing the main chemicals are binders of different make ie acrylic and
In addition to skins and chemicals other materials that are required in a tannery
like Z factory include water, lubricants, fuel, diesel, packaging materials and
the consciousness of the company to protect the health of its employees as well
4) Contingency plan
5) Safety plan
8) Reporting plan
led by a project manager and consists of staff members of Z Tannery limited and
a representation of the community. The unit is responsible for ensuring that the
responsibilities and obligation of the EMP is satisfied. Also the unit coordinates
Because liquid effluent forms a great proportion of the waste generated and to
comply fully with the legal requirement to have a primary treatment plant, Z
Tannery established a waste water primary treatment plant with the waste water
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collection pond.
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care to the health and well-being of staff, Z Tannery makes it mandatory for all
Environmental Reporting
Contingency plan
Safety plan
Plan Review
The following among others are laws and regulations that are applicable to Z
Tannery limited
Laws of the Federation of Nigeria 1990, Labor ACT CAP 198 Relating to
Business premises registration LAW (CAP, 18) 1992 section 4(1) of Kano
state Government
1998section 7 (5)
Polluter fee
The following are the results of observations and data collected in respect of the
operations of Z Tannery.
The following are the wastes that are generated from the manufacturing
process in Z Tannery:
Liquid waste
Solid waste
Trimmings
Fleshings
General sweepings
Gaseous waste
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Noise
waste water after primary treatment through the main drainage outlet that
ultimately gets into Challawa River. This method of disposal has its attendant
comparison with NESREA standard for waste water from tanneries, showing
organic substances are present, many of the substances in the wastewater from
Z Tannery are resistant to bacterial action and the breakdown may be very slow.
guidelines.
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A substantial amount of sludge consisting of fleshing and solid residue from the
liming made up of broken hair and other ancillary product such as plastic and
paper from packaging, residue of various chemical and greases are the major
constituents. A further component of the solid is dust from the buffing operation
as well as general sweepings. Data indicated that about 2300kg of these wastes
land surface within the factory and is eventually evacuated after the box made
up of block is filled up. It is expected that when the waste slowly percolate
through the soil and gradually undergo oxidation by soil bacteria it would result
in the formation of harmless end products. However, it was observed that this
practice requires large areas of land that the company currently does not have;
it leads to bad smell; may contaminate underground water and can ultimately
lead to poor agricultural productivity of the land. Also the polluted groundwater
eventually flows into a drinking water well or river resulting in the spreading of
waterborne diseases in the long run. Therefore remedial measures are required
immediately
4.1.2.3 Compatabilty
The factory is located in Challawa industrial estate and is thus compatible with
the existing approved land use of section 3.2 of the National policy on
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4.1.2.4 Cloakroom/Conveniences
There is adequate cloak room, but for the female employees who are about
15% of the total work force, there is need for separate toilets for them.
There are no enough safety signs to warn staff and visitors within the factory.
There is a muster point centrally located by the main gate with clear sign
There are sufficient Fire extinguishers within the factory, but clear signs are
required
Noise level within identified units of the Z Tannery were measured and
compared with the NESREA permissible limits are shown in Table 3. Most units of
the Z Tannery is within the limit but the area in the vicinity of the generating
room which also houses, the workshop and ETP are well above the limit and
considering the presence of workers all the time in the area constitute a risk to
Air qualities within identified units of Z Tannery were measured as shown in Table
4. Most areas of the Z Tannery has emission of gases within the limit but the
observed variation not only indicated differences in the levels of air quality, but
also potential problem that require attention especially the area in the vicinity of
Kano is known for its traditional leather and is famous in the tanning sub-sector
exported to Europe and Asia. Also, the artisanal producers convert finished
leather for domestic finished leather goods markets. Kano state has abundant
production for leather and leather products existed for many years in Kano.
Leather and leather products are among the most widely traded and universally
used commodities in the world. Already, the total value of annual trade is
estimated at 1.5 times the value of the meat trade, more than five times that of
coffee and more than eight times that of rice. In Nigeria, according to the
Federal Ministry of Industry, Trade and Investment, leather has overtaken Cocoa
as the second biggest foreign exchange earner for the country. A study by
Chemonics International Inc. prepared for the United States Agency for
industry export worth $43.4 billion is begging for investors. According to the
Report filed by Business Day, the industry is believed to be worth about $4.4
Billion for raw hides and skins, $14 billion in rough-tanned and finished leathers of
all types and $25 billion for footwear with leather uppers. This indicates high
production in Nigeria is still less than 40% of the potentials that exist in the tanning
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Section 8 (k) of the NESREA establishment Act also empowers the Agency
Management plan (EMP) which has been submitted to NESREA and now
an Environmental Audit.
Z Tannery needs to consider both the short and long term environmental
development
areas surrounding the effluent treatment and waste water holding tanks
beauty of the surrounding by planting flowers and trees that could also
serve as a sink
bins of different colors with a view to recovery of such waste based on the
The importance of the Materials safety data sheet for the different raw
savings.
Steps should be taken to ensure that empty cans are fully drained.
Leaking oil from the bearings of drums and other equipment should
subsequent batches.
slotted cages where it is left to drain for a week. The dried sludge
50,000 skins/ week. In the past, these fleshing were collected in skips
5.2.5 Retention/redirection
This simply means determining uses for wastewater other than discharge.
wastewater as a fertilizer for plant grass areas. These approaches require close
5.2.6 Separation/concentration
This should involve separating out solid or other materials from wastewater. Low-
Specific water consumption is the volume of waster used per unit of production,
products. Establishing these figures will allow the industry to compare the
water the industry is using, it is also useful to know how this consumption relates
is within industry limit or not. Above industry limit means the company is wasting
look for wealth from waste. For example because of the process by which
sewage collected, the solid content varies from 2-4%. They need to be pre-
biogas so obtained can be used in engines. Clean sewage based biogas has
400-1500 ppm of hydrogen sulfide. Mixed sewage based biogas has 1-3%
reduce high noise level. They should also be overhauled and serviced as at
local, state and Federal legislations that are either in force now or will be
enacted from time to time. Z Tannery must ensure that it is in compliance with all
Z Tannery must put in place good cleanliness of its premises; ensure that all staff
are provided with appropriate uniforms and that they use them at all times;
illuminations in all sections of the factory; Explicit signs in strategic sections of the
factory identified