label eco-efficiency analysis ibuprofen - basf · in accordance with iso 14040 - 14043. …...

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Eco-Efficiency 106.05.2004

BASF Aktiengesellschaft Product Safety Regulations, Toxicology and Ecology

Validated Eco-EfficiencyAnalysis Methodology

Label

Eco-Efficiency Analysis

Ibuprofen

May 6th, 2004

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The Label

An eco-efficiency analysis was performed in order to compare the environmental impactsand the costs from all life-cycle stages of the production of ibuprofen. Ibuprofen is used in over-the-counter pain relief medicines in the United States. The main production locations for ibuprofen powder are the U.S., India and China.The eco-efficiency analysis showed that production of ibuprofen powder at BASF‘s Bishop, Texas manufacturing facility is the most eco-efficient method.

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Requirements Met

1. Accomplished Eco-Efficiency Analysis according to the methodology certified by TÜV Rheinland/ Berlin-Brandenburg, Germany.

2. Verification of the investigated production method to be more eco-efficient than other alternatives for the production of ibuprofen.

3. Third party evaluation by Prof. D. R. Shonnard, PhD, Michigan-Technological University, Houghton, MI (USA)(so-called Critical Review according ISO 14040 ff.).

4. Publication of the results via internet on website www.oeea.de, which is referred to on the label.

5. Payment of the licence fee for the duration of three years.

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Certificate

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Objectives and Planned Use of the Study

Target groups of the study– BASF Research– Decision-maker BASF – Customers– Public

Use of the study– Internal strategy finding– Identifying of weaknesses and

strengths– Marketing

Objective of the studyAn eco-efficiency analysis was performed in order to compare the environmental impacts and the costs from all life-cycle stages of the production of ibuprofen.

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Ibuprofen

• Ibuprofen produced by BASF in U.S.A.

Customer benefit(CB)

BASF Product Comparable Products

• Ibuprofen produced via:•Acetylchloride & cyanhydrine chemistry in U.S.A (U.S. Competitor)•Acetylchloride, glycidesterand Cr(VI)-oxydationchemistry in India •Chlorpropionylchloride and rearrangement chemistry in China

• Production of 1kg of ibuprofen for use in over-the-counter pain relief medication to besold in the North American marketplace.

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System boundaries for Ibuprofen

UseProduction

Transport

Tabletting

Packaging

Retail sale

Consumption

Disposal of Production Residues

Raw MaterialsProduction

Ibuprofen Production

Disposal

Production of Inactive

Ingredients

Production of Packaging Materials

Grey boxes are assumed to be the same for all alternatives and therefore are not calculated.

Post-Consumer Packaging Disposal

Transport

Transport

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Base Case Assumptions

• Components present at <1% by weight are not considered.• Transportation distances for raw materials upstream of the

Ibuprofen production are assumed to be equivalent.• Environmental, industrial hygiene and safety controls are

significantly more stringent in the U.S. This is based upon site visits, typical industry practices and regulatory requirements.

• Toxicity potential of Ibuprofen consumption is assumed to be the same for the alternatives, except for the paraben content. Indian Ibu contains on average 350ppm of paraben, which is an average of several samples which were analyzed.

• Indian and Chinese manufacturing practices are based upon plant visits and the chemistry used.

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Data Quality I• Data used for this study is current. Data sources such as market

intelligence reports, site visits and air permits are from the 2002 time period.

• Data for the different ibuprofen producers correspond to the geographic region in which they are located. Process data are based upon intelligence information obtained from or about thoseproduction facilities. Auxiliaries such as electricity or diesel fuel correspond to the geographic region of the manufacturing facility using modules in the Boustead database.

• The ibuprofen production data is representative of actual processes. Data were either directly obtained from a manufacturing facility or estimated based upon known chemistry.

• Data for raw material inputs are high quality. They are either based upon BASF manufacturing facilities, or estimated by BASF experts based upon known Ibu chemistry.

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Data Quality II

• Data for energy consumption are of medium quality. They are based upon operating facilities, former manufacturing processes or benchmarking studies. Energy generation data are high quality as they are based upon the Boustead regional energy mix.

• Data for health effect potential are of medium quality. Quantities of raw materials are of high quality, as described above. However, not all material hazards are known, as is the case in general in the toxicity field.

• Data for risk potential are qualitative, but are believed to be of high quality. They are based upon site visits and knowledge of typical industry standards in the various geographic regions.

• Data for process emissions are medium quality. Process emissions are based upon known process chemistry and assumptions of removal or destruction efficiencies for the waste streams. Energy use emissions come from the Boustead database.

• Although there are some assumptions in the input data, the study results are robust. Because the Chinese and Indian producers are much worse in all six ecological categories, uncertainties in one or two of the categories do not change the overall relative eco-efficiencies.

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Eco-Efficiency Portfolio

Portfolio

0.3

1.0

1.80.31.01.8

Costs (normalized)

Envi

ronm

enta

l Im

pact

(nor

mal

ized

)

BASFU.S. competitorIndiaChina

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Interpretation of the Eco-Efficiency Portfolio

• Ibuprofen produced by BASF is the most eco-efficient.

• BASF ibuprofen has the least environmental impact: it is made by the most efficient production process, uses the least hazardous materials, and is produced under rigorous quality, environmental, safety and industrial hygiene controls.

• From the customer’s point of view, the domestically produced ibuprofen costs more than ibuprofen produced in India or China (market prices at the end of 2003 are reflected on the portfolio). The domestic producers allocate significant resources to optimizing their processes, maintaining and operating their equipment to prevent any possible contamination, ensuring that the environment and the workers are protected, and complying with stringent governmental regulations and quality standards.

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EcologicalEcological FingerprintFingerprint

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EcologicalEcological FingerprintFingerprint -- Base Base CaseCase

1,0 = worst position, relatively better position <1

0.00

0.50

1.00energy use

emissions

health effect potential

risk potential

material use

land use

BASF

U.S. competitor

India

China

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Toxicity Potential Production (Raw materials)

0

500

1000

1500

2000

2500

BASFU.S. c

ompetitor

India

China

Hea

lth e

ffec

ts o

f pro

duct

ion

[Sco

re]

Zinc oxide production WasserstoffTriphenyl Phosphine Solution (20%) ToluolSulfuric AcidSodium Hydroxide Solution (20%) p-ToluolsulfonsäureNeopentylglycolNatronlaugeNaphthaKohlenmonoxidIsopropanolIsobutylbenzene Hydrochloric acid production 36% Hexan EthanolChromium-(III)-oxide Chlorw asserstoffgasChloressigsäuremethylesterCarbon black production AluminiumtrichloridAcetyl Chloride AcetonAcetanhydrid2-hydroxy, 2-(4-isobutylphenyl) methyl pr1,1-dichloroethane

Toxicity potential includes all upstream components used in the manufacturing process. Here the toxicity potential during production is much less for the U.S. producers because they use “closed” manufacturing systems, which protect the workers from exposure to the materials being handled.

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Risk PotentialProduction

0

20

40

60

80

100

120

BASFU.S. c

ompeti

tor

India

China

Ris

k [S

core

]

Process Upsets - Harm to HumansContamination PotentialProcess Upsets - Damage to the EnvironmentStorage AccidentsTransport AccidentsFlammabilityRisk of Explosion

Use

0

1

2

34

5

6

7

BASF U.S.competitor

India China

Disposal

0

5

10

15

20

25

30

35

BASFU.S. c

ompeti

tor

India

China

Accidents during disposal of production waste streams

Production Waste Streams Impact on the Environment

Risk potentials during production and disposal reflect the quantities of hazardous materials and the safety and environmental controls that are present. During the use phase, the most significant differentiating factors are the transportation distances and the safety and environmental practices in place.

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Critical ReviewBASF´s eco-efficiency was carefully examined and evaluated by David R. Shonnard, PhD, an independent expert in green engineering. Dr. Shonnard is a Professor at the Department of Chemical Engineering at Michigan-Technological University, Houghton, MI (USA). He is a co-author of the textbook "Green Engineering: Environmentally Conscious Design of Chemical Processes", published by Prentice Hall, 2002.

Excerpt from the report summary:“…Overall, the inventory data for materials utilization and emissions is based on the most accurate information available. Inventory data came from industry market watch reports, air permit applications, site visits, facility reports, and estimates using best engineering judgment by BASF professionals. …

The main conclusion that Ibuprofen produced by BASF is more eco-efficient compared to production at the other producers is consistent with the goals and assumptions of the study. The results of the study are highly credible. The entire study has been made in accordance with ISO 14040 - 14043. …

Eco-efficiency analysis, as applied in this study, is the best methodology for the stated purpose of this comparison of Ibuprofen manufacturers. The analysis provides a broad evaluation of environmental, resource consumption, risk, toxicity, and cost effects. Taken together, these effects allow for a comprehensive analysis and provide a broad range of information for decision-making…”

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Contact

For more information about Ibuprofen please contact:

Jack ChenBASF CorporationN-MEN/SF+1 973 426 [email protected]

For more information about the eco-efficiency analysis please contact:

Charlene WallBASF CorporationNT/U-R+1 973 426 [email protected]

label eco-efficiency analysis ibuprofen - basf · in accordance with iso 14040 - 14043. …...

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