Environment and Safety
Challenge to Reduce Product Carbon Footprint by 46%
Realizing Optimized Visualization for Customers
In recent years, customers have started putting more importance on environmental added value when choosing a product or service in addition to the usual considerations of quality and price. Under these circumstances, there is growing interest in systems that convert GHG emissions throughout the product life cycle into CO2 and display them in an easy-to-understand manner (product carbon footprint, hereinafter PCF). Polyplastics also receives the requests from our customers to disclose and reduce PCF.
To meet these needs, we have set ourselves the challenge of reducing our PCF by 46% (cradle-to-gate basis) by 2030, compared to 2013 levels. As the first step toward achieving this target, we completed the calculation and the preparation for disclosure about PCF for more than 90% of our product grades in 2022 (grades sold in FY2021).
Beyond Visualization
PCF is calculated in line with the ISO 14067, and it is very important to consider the type of input data, the accuracy of emission factors, and how to calculate the PCF of biomass raw materials or waste materials. For example, if general-purpose inventory data is used instead of the latest primary data representing the actual state of raw materials and fuels, it will be impossible to accurately measure the effect of PCF reduction. Therefore, it is important to use as much of the latest data as possible to ensure accuracy. Also, for internal emissions (Scope 1 and 2), it is necessary to establish a system for PCF calculation with rational boundary setting and accurate data aggregation as the foundation for steadily promoting PCF reduction activities.
In FY2022, we began working towards these challenges, and now we are able to accurately calculate PCF, provide information to customers, and conduct reduction activities going forward. Furthermore, we have also established a system that provides PCF calculation results using customer relationship management (CRM) for prompt disclosure to our customers.
Entire Supply Chain Working Together as One Team
Now that our PCF calculation is completed, the next step toward 2030 is to reduce PCF. For the processes in which we manufacture our own monomers and polymers, we will actively promote energy conservation and energy conversion to reduce PCF. On the other hand, achieving our PCF reduction targets will also require enormous support from all of our business partners, including raw material and other material suppliers, transportation company, and subcontractors. We will share our ambitious goal throughout our supply chain and will work together as one team to implement visualization and reduction activities.
Our Own Future Initiatives
- Energy-saving at plants
- Plant advanced controlAdvanced Control Technology to TOX process
- Introducing production processes that use even less energy
- Recovery and reuse of waste heat, etc.
- Energy conversion
- Making materials sustainable
Using CO2 as a resource for engineering plastics
etc.
Future Initiatives with Business Partners
- Reducing CO2 emissions with raw material suppliers
- Considering fillers and additives with smaller PCF
- Reducing CO2 emissions during transport
etc.
Taking One More Step
Not only the “Cradle-to-gate” PCF of our products, but also the amount of “Avoided Emissions” of our products is important for society. (Example: Contribution to the reduction of CO2 emissions by improving the fuel efficiency of automobiles with parts using our products) Therefore, it is also necessary for us and our customers to work on product development as a “one team.” Until now, we have worked to improve fuel efficiency and resource savings by helping to make our customers’ products smaller, lighter, and longer lasting. However, going forward, we will enhance customer collaboration from the design and development stage and propose innovative solutions to further reduce environmental load.
Air Conditioning System Utilizing Well Water
In FY2022, for the first time in about 30 years,* we built a new compound plant at the Fuji Plant.
Since the location for the new facility is near a residential area, this building was constructed with materials with high thermal and acoustic insulation to minimize noise leakage and odor. There were also concerns that the building would be too hot inside during summer.
To prevent heatstroke, we introduced an energy-saving air conditioning system that makes effective use of well water. This system uses less energy than normal air conditioning to cool the air by exchanging heat between the cold temperature of the well water and the hot temperature of the intake air from indoors. In this system, impurities are not mixed in the well water, therefore it can be still utilized as industrial water after being used for air conditioning.
The amount of well water used at the Fuji Plant will remain the same, and we have already confirmed in advance that there will be no adverse effects on land subsidence, water sources, or wastewater.
The air conditioning system will start operation in the summer of 2023.
- *First expansion construction with new building in 14 years, and first expansion of a line for compounding in 31 years.
Award for Excellence in Odor Control
In FY2022, the Nantong Plant (China) received an award for excellence in odor control from the government of the Nantong Economic and Technological Development Area (NETDA). We were selected as one of the first 10 out of the 70 companies within the NETDA to receive the award.
The Polyplastics Nantong Plant has been recognized for its employees’ active participation in proposing improvements to odor prevention in the manufacturing process, and for the teamwork among departments in implementing such improvements. The plant manager committed human, material, and financial resources to these activities, and this was praised highly and was a main factor in receiving the award. Going forward, we will continue optimizing our manufacturing processes to reduce odors, and regularly communicate the importance of such activities.
Examples of Odor Prevention
Covered the wastewater treatment tank to collect and process odors
Installed 52 closed samplers to reduce the exhaust gas generated during the sampling process
Odor leakage prevention measures have been implemented at approximately 500 discharge points in total to prevent odor leakage
Utilizing a Green Loan for New Plant Construction
Polyplastics Group company DP Engineering Plastics (Nantong) Co., Ltd., located in Nantong, China, is constructing a new POM plant with an annual production capacity of 90,000 tons. The new plant will implement a manufacturing process with a lower environmental impact than our existing plants in China, and we expect the following results.
These points were highly praised, and we were able to procure a Green Loan for a portion of the construction and operational funds for the new plant. The Green Loan has been externally certified by the Hong Kong Quality Assurance Agency for compliance with both international and Chinese standards.
Going forward, we will use the Green Loan fund to advance the construction and operation of the new plant, and we will work with our business partners to implement operations in harmony with the environment.
Air and Water Pollution Prevention
At the Fuji Plant, we perform continuous monitoring and regulatory compliance for the followings in order to prevent environmental pollution caused by air pollution substances or waste water generated from plant.
Held the Environmental Monitoring Meeting
At the “Environmental Monitoring Meeting” held at the Fuji Plant in June every year, we explain the environmental efforts of the Fuji Plant to local residents. Also, we invite them to see our environment-related facilities in the plant, exchanging opinions. Due to the COVID-19 pandemic, the event was held in 2022 for the first time in three years and was attended by 16 representatives from six nearby districts.
Participant Comments
“I was relieved to learn that a variety of preventive measures are being taken against environmental pollution on the tour of the plant facilities as well as the environmental report. Especially with the noise and smell pollution from the plant, it is so quiet and odorless that we don’t notice it in our daily lives. I was also impressed that Mr. Sanada (the plant manager at the time) as well as every employee valued dialogue with us. I’m looking forward to the collaboration between the plant and our community in the future and Polyplastics' continuing environmentally friendly business activities.”