Case Study

Reducing solvent emissions at ulverston, UK

We use a wide-range of solvents (volatile organic compounds) in the manufacture of Epivir (an antiretroviral), Zinacef and Zinnat (cephalosporin antibiotics) at our site in Ulverston, UK.

We endeavour to use these solvents in a sustainable manner and over 20,000 tonnes of solvent are recovered each year at the Ulverston site for re-use in the manufacturing processes.

We have been working for a number of years to reduce releases of all solvents, including dichloromethane, at the site. In February 2003, the site produced a Solvent Management Plan and Substitution Plan - in line with the requirements of new EU regulations. These were updated in July 2004.

The site is authorised under the UK Environmental Protection Act 1990 to release a maximum of 1,000 tonnes of dichloromethane to air. In 2004, emissions to air totalled 269 tonnes - well below the limit and a reduction of 33% compared with 2003. Over the same period releases of other VOCs reduced by 10% and have declined by 30% over the last five years. Our target is to reduce emissions of dichloromethane to air to less than 190 tonnes in 2005 and 80 tonnes in 2006.

In 2004, we also reduced the amount of dichloromethane discharged into water by 80% compared with 2003. We aim to reduce this amount to below one tonne in 2005 and below 0.1 tonnes in 2006.

Dichloromethane continues to be used in enclosed equipment and regular monitoring of employees ensures their exposure levels remain low. The levels of all solvents, including dichloromethane, found around the edge of the site are well below guide limits set by the Environment Agency for England and Wales.

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