CENTURY RAYON

Environmental and Occupational Health & Safety Policy

Century Rayon is the leading manufacturer of Viscose Filament Yarn and Chemicals. The
company is committed to the protection of the environment and the health and safety of its
employees, customers and community.
In this vein the company shall:
Regularly review objectives for attaining continual improvement in environmental and
occupational health and safety performance.
Be committed to prevention of pollution.
Implement continual improvement in resource conservation i.e.: Raw Materials and
utilities like Energy and Water.
Take measures and ensure safe work environment towards reduction of accidents.
Monitor and control work place hazards.
Train and involve company's employees and contractor's workmen in Environmental and
Occupational health and Safety performance.
Ensure compliance of legal and other requirements and strive for further improvement.
Century Rayon is committed for a cleaner and healthier environment.
The Environmental and Safety Policy shall be communicated to all persons working for or
on behalf of the organization and is available to the public on request.

Date: 28.2.2007 President

 CENTURY RAYON
Environmental & Occupational Health & Safety Management System
Overview
ISO-14000 is a series of international, voluntary
environmental management standards for better environment
management.

OHSAS-18000 is a set of authorities through which an

organization maintains awareness & control over its
interactions with worker health & safety.

Interfaces directly with business objectives

 CENTURY RAYON
Definations
Environmental Aspect: Element of organizational activities or products or
services that can interact with the environment.
Environmental Impact: Any change to the environment whether adverse or
beneficial wholly or partially resulting from an organization’s environmental
aspects.
Hazard: Source or situation with a potential for harm.
Risk: Combination of the likelihood & consequences of a specified hazardous
event.
SSPD Score: Product of individual weightages of scale, severity, probability &
duration.
EMP: Environmental & Occupational Health & Safety management program
includes objectives, targets & action plan.
EPR: Emergency preparedness & response for potential emergency situation &
accident.
M&M: Monitoring & measurement of key characteristics that can have
significant impact / harm.
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

1 Process flow sheet – aspects to be linked to process flowA. / H. no.

activity. included
2 Cross Reference for aspects / significant aspects &Implemented
objects/ targets / programs
3 Aspect of contributing factor to be rated Implemented
4 Procedure for issue, distribution & maintenance of PPE Implemented
5 External origin documents to be identified & records toImplemented
be maintained.
6 Objectives to be displayed and communicated throughImplemented
training.
7 Incident report, Frequency Report, Severity Report,Implemented
Trend charts of near misses , incidents & accidents
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

8 Toe Guard for stair cases. Implemented

9 OCP to be modified as per clause 4.4.6. Implemented
10 Environmental program - procedure to be modified forImplemented
review, changes, benefits & closure of EMP
11 ETP - control measures to be provided for fall hazards. Implemented
Plan for DO probe in aeration tank. Aspect & impact
evaluation of foam suppression
12 Basic risk, residual risk with existing control, riskNew format
classification & corresponding control plan to be includedfor Evaluation
in the procedure.
13 M & M plan with frequency & for Key EnvironmentalImplemented
performance Indicators (Water, power & Air etc.)
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

14 Companywide power consumption. 1% Reduction

taken as an
objective.

15 Trend of Environmental performance improvement. Implemented

16 Procedure for legal requirement to include updating,Implemented
responsibility for liaison with statutory bodies, M & M
etc.
17 Evaluation of compliance- Legal / Statutory regulatoryImplemented
requirement. (PCB Act, Bio medical waste, MV Act,
Battery Rules etc.)
18 M & M (Legal) to be maintained at one definedImplemented
department.
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

19 M & M for maximum permissible discharge limit ofImplemented

sewage - evidence to be provided.
20 Management programs for sewage treatment withNot Required
defined action plan.
21 Recycling of treated water & discharge of excess quantityImplemented
through Waldhuni nallah - evidence to be provided.

22 The quality & quantity of treated effluent discharged toImplemented

ulhas river thru waldhuni nallah - evidence to be
provided.
23 The quality & quantity of effluent from each plant to ETPUnder
to be measured and monitored - plan to be definedProgress
against set norms.
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

24 Water consent order Form No. 5 - consumption forImplemented

Industrial cooling - evidence to be provided.
25 License for sulphur storage - evidence to be provided. Available
26 Monthly Form 3 of PCB to be filled for inventory / stocksNot Required
of hazardous waste.
27 Non-ferrous metal waste - to be included in form 13. Implemented
28 Investigation format for incident/ accident to include 4.5.2Implemented
clause of OHSAS 18001.

29 Water Budget, Water balance as per permitted quantitiesImplemented

by MPCB - evidence to be provided.

30 Chlorine leaks , CS2 leaks , fire due to inflammableImplemented

material to be included in onsite emergency plan.
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

31 Management programs for storage of waste oil. Under

progress
32 Hazards during cement unloading. Implemented
33 Identification of hazardous waste chemical containers. Implemented
34 Compressed gas cylinder - legal requirement for capping,Being taken as
color coding & safety distance, test date and due dates toEMP
be displayed on cylinders.
35 Housekeeping in scrap yards. Implemented
36 Procedure for maintenance including plant - dustImplemented
collectors, scrubbers, blowers, ETP equipment - records
to be maintained. Test records from external agency for
chain pulley blocks & EOT Cranes.
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

37 Training - Contractors, material movers, sub-contractorsUnder

& transporters - for outside & inside people. Progress
38 Training Calendar to be made Implemented
39 Policy & Compliance with legal requirements to beUnder
displayed outside. progress
40 Receiving, documenting and responding toImplemented
communication from public to be updated & recorded
41 ISI marking on First aid & Fire fighting equipments Implemented
42 Canteen – Aspects & Hazards due to LPG leaks, fire dueImplemented
to diesel storage, OCP for pest control, license for LPG
cylinder storage
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

43 Dust collectors - OCP for downtime analysis, PMImplemented

schedules, spare parts & efficiency measurements
44 List of E & S critical equipments – down time analysis ofImplemented
ETP, dust monitors,& efficiency measurements – records
to be maintained.
45 Drawing/Plot plan indicating domestic sewage lines,Implemented
process waste lines, storm water drains, septic tank
locations, ETP location, ambient air monitoring station,
noise monitoring stations, hazardous storages, evacuation
routes, entry, exits & assembly points. Sign boards at
emergency exits to be provided

46 Management Review – Agenda to be reviewed to includeImplemented

clauses
 CENTURY RAYON
Pre-audit Observations of M/s TUV
Sr. No. Particulars Remarks

47 Documentation System , Levels of Documentation,Implemented

Review, Approval & Issue matrix.
48 Master List of Documents & records. Implemented
49 Drinking water analysis – Chemical & Bacteriological –Implemented
As per ISI Standards.

50 Laboratory – Hazardous chemicals to be considered forImplemented

Aspects / Impacts.
51 Overall Roles & Responsibility – As per the Clause Implemented
 CENTURY RAYON
DETAILS OF NON-CONFORMITIES – CLOSED
(ROUND NO. 1)
1. Rayon Viscose (Production)

In GCF section no SSPD analysis carried out and aspects

/hazards are made significant without analysis.

2. Century Chemicals Laboratory

Temperature is abnormal in chemical laboratory. It is

unhygienic for staff and workmen especially during summer.
 CENTURY RAYON
Tyre Cord Plant
Pulp Ratio – Apr ’05 to Mar.’07
1.036 1.035
PULP (Kg./ Kg. Yarn)

1.034
1.031
1.032
1.030
1.028 1.028
1.028
1.026 1.026
1.026 1.026
1.025
1.026
1.026
1.024 1.0251.023 1.026

1.022
May '06

July '06

Jan.'07
Apr'05- Mar'06

Nov. '06

Mar.'07
Oct.'06
Apr '06

Sept. '06
June '06

Aug.'06

Dec. '06

Feb.'07
Year
 CENTURY RAYON
Tyre Cord Plant
Power Ratio – Apr ’05 to Mar.’07
3.800
3.77 3.67
POWER (KWH /Kg. Yarn)

3.700 3.62
3.600
3.58
3.500 3.39
3.4
3.400 3.43
3.27
3.300 3.2 3.31
3.200
3.12
3.100
3.000
2.900 2.92
2.800 2.8
2.700
July '06
Apr '06

Aug.'06

Nov. '06

Jan.'07
May '06

Oct.'06

Mar.'07
June '06

Sept. '06

Feb.'07
Dec. '06
Apr'05- Mar'06

Year
 CENTURY RAYON
Tyre Cord Plant
Caustic Ratio – Apr ’05 to Mar.’07
0 .7 6 5 0.760
CAUSTIC (Kg./ Kg. Yarn)

0 .7 5 5
0.70.746
48 0.747
0 .7 4 5
0 .7 3 5 0.7 30
0.725
0.73 0
0 .7 2 5
0.717
0.7140 .720
0 .7 1 5 0.717
0.7 11

0 .7 0 5
0.706
July '06
Apr '06

Aug.'06

Jan.'07
Nov. '06
Oct.'06
May '06

Feb.'07
Mar.'07
June '06

Sept. '06

Dec. '06
Apr'05- Mar'06

Ye a r
 WATER (Gallons)

24
26
28
30
32
34
36
38
40
Apr'05- Mar'06

30
Apr '06

32
May '06

33
June '06
38

July '06
32

Aug.'06
28
36

Sept. '06

Year
Oct.'06
39

Nov. '06
37

Dec. '06
37

Jan.'07
Tyre Cord Plant

38

Feb.'07
39

Mar.'07
28
CENTURY RAYON
Water Consumption – Apr ’05 to Mar.’07
 CENTURY RAYON
Tyre Cord Plant

22.50
Steam Ratio – Apr ’05 to Mar.’07
22.31
STEAM (Kg./ Kg. Yarn)

22.00 21.51 21.53

21.50 21.47 21.07
21.00 20.52
20.77
20.50 20.73 20.35
20.66
20.00 19.77
19.58
19.50
19.00
18.50
18.21
18.00

Nov. '06

Jan.'07
Apr '06

Aug.'06

Oct.'06

Feb.'07
May '06

July '06

Dec. '06
June '06

Sept. '06

Mar.'07
Apr'05- Mar'06

Year
 CENTURY RAYON
CSY Plant
Pulp Ratio – Apr ’05 to Mar.’07
1.120
1.115
PULP (Kg./ Kg. Yarn)

1.110
1.105 1.100
1.100 1.095
1.090
1.080
1.080 1.075
1.075
1.070
1.065 1.067 1.065
1.060 1.060
1.059
1.050
1.044
1.040
May '06

July '06

Nov. '06

Jan.'07

Mar.'07
Apr'05- Mar'06

Apr '06

Aug.'06
June '06

Sept. '06

Oct.'06

Dec. '06

Feb.'07
Year
 CENTURY RAYON
CSY Plant
Power Ratio – Apr ’05 to Mar.’07
6.200
POWER (KWH /Kg. Yarn)

5.86
5.900 5.74
5.600 5.43
5.48
5.300
5.11 5.27
5.000 4.74
4.700 4.53
4.46
4.400
4.100 4.05 3.83 4.16
3.800 3.94

3.500
Apr'05- Mar'06

July '06

Nov. '06
Aug.'06
Apr '06

May '06

Jan.'07
June '06

Sept. '06

Mar.'07
Oct.'06

Dec. '06

Feb.'07
Year
 CENTURY RAYON
CSY Plant
Caustic Ratio – Apr ’05 to Mar.’07
0.655
0.650
CAUSTIC (Kg./ Kg. Yarn)

0.645
0.640

0.635 0.630 0.630 0.630 0.630 0.630

0.630
0.625 0.630
0.625 0.625
0.625
0.620
0.615
July '06
Apr '06

Aug.'06

Jan.'07
Nov. '06
May '06

Oct.'06

Mar.'07
Feb.'07
June '06

Sept. '06

Dec. '06
Apr'05- Mar'06

Year
 WATER (Gallons/ Kg. Yarn)

38
40
42
44
46
48
50
52
54
56
58
60
62
Apr'05- Mar'06

49
Apr '06

48
May '06

42
June '06

39
July '06

39
Aug.'06
42
Sept. '06

Year
47

Oct.'06
50

Nov. '06
CSY Plant

54 56

Dec. '06

Jan.'07
56

Feb.'07
60
61

Mar.'07
CENTURY RAYON
Water Consumption – Apr ’05 to Mar.’07
 CENTURY RAYON
CSY Plant
Steam Ratio – Apr ’05 to Mar.’07
44.00 43.69
41.62 43.29
42.00
STEAM (Kg./ Kg. Yarn)

41.19
40.00
39.56
38.00 37.01
36.02
36.00
35.29 34.81
34.00
32.09
32.00
30.87
30.00
28.63 28.26
28.00

Oct.'06

Nov. '06

Jan.'07

Feb.'07
Apr '06

Aug.'06
July '06

Dec. '06
May '06

Mar.'07
June '06

Sept. '06
Apr'05- Mar'06

Year
 No. of Accidents

0
1
2
3
4
5
6
Avg. (2005)

3
Jan '06

4
Feb. '06

3
Mar.'06
5
Apr. '06
4
May '06
June '06 2
3

July '06
2

Year
Aug. '06
4

Sept. '06
4

Oct. '06
2

Nov. '06
2

Dec. '06
1

Jan. '07
5

Feb. '07
( Including Contract Workers )

Mar.'07
CENTURY RAYON
ACCIDENTS IN TYRE CORD PLANT
 CENTURY RAYON
Master List of Objectives & Targets
Tyrecord

Viscose (P) To reduce CSY pulp ratio From 1.080 to 1.070

To reduce the total Energy consumption From 12000 kwh to
11880 kwh
Spinbath (P) To reduce Steam consumption of Tyre Yarn From
20 Tons/Ton of yarn to 19.5 Tons/Ton of yarn
To reduce Filtered water consumption From 350000
gallons/day to 300000 gallons/day
Spinning (P) To reduce water consumption By 5%
To minimise viscose waste due to idle positions By 5%
Textile (P) To reduce the Mandays loss due to accidents to nil
Maintenance To reduce the total Energy consumption From 1.5 KW to 1.1 KW
To reduce the water pollution