the remake project: recycling and resource efficiency in manufacturing forum on environmental goods...
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The REMake project:Recycling and resource efficiency
in manufacturing
Forum on
Environmental Goods & Services and Green Business ModelsBrussels, 15 October 2010
The REMake consortium
A public-private partnership comprising:o National and regional innovation agencies;o Industrial associations;o Technical centres;o Innovation experts.
REMake partners come from Belgium, France, Germany, Hungary, Italy, Spain and the UK.
Be more profitable by simply using less resources
Enable manufacturing SMEs to:o Access state-of-art expertise in recycling and
resource efficiency;
o Assess their resource savings potential;
o Develop and test innovation vouchers, as an un-bureaucratic innovation support tool on resources efficiency and life-cycle approaches.
Recycling and Resource Efficiency in manufacturing
In a medium-sized manufacturing company, material consumption represents 40% of operating costs (personnel costs = 20%).
Major gains are achieved tackling RRE at three key levels of innovation:o Product design;o Process efficiency;o Value chain optimisation.
CASE STUDIES
Redesign of electric ovens - France
Problem:o Operational costs;o Environmental impacts.
Measures:o Redesign of the ovens using a set of environmental indicators;o Reduction of the number of components (36%) and external
volume (25%).
Results:o Reduction of effluents (44%);o Reduction of water (18%) and energy (35%) use;o The ovens are now 3 times less noisy.
Brecon Mineral Water - UKProblem:o Error-prone packaging schemes;o Unnecessary use of resources.
Measures:o Lightweighting the bottles by 1g each and redesigning them,
increasing its number per pallet;o Reduction of the thickness of low-density polyethylene that
wraps multi-packs;o Reduction of label size and changing in the gluing system.
Results:o Saving of 84 tonnes of plastic and 10 lorry loads in a year;o Saving of 1 tonne of paper and 60-70% of glue.
Closed-loop recycling in households - UK
Problem:o Operational costs;o Environmental impacts.
Measures:o Use of 100% recycled plastic (recovered from domestic fridges) in
washing machines’ access panel;
Results:o Same production cost for the recycled parts;o 5% saving in raw material costs;o Significant amount of CO2 emissions avoided;o Savings in cumulative cost and raw materials over the 500 000
parts produced each year.
Metal processor - GermanyProblem: o High quantity of chipping waste;o High wear of tools and instruments.
Measures:o Application of pre-casted raw material instead of solids.
Results:o 50% reduction of waste material;o Decreased wear of tools by lowering chipping power;o Efficiency improvement by reduction of processing time;o 2.37 Mio € possible savings;o 13.7% increase of annual rate of return.
Packaging process - Germany
Problem:o Inappropriate transport;o Error-prone packaging schemes;o Mistakes at protection and handling.
Measures:o Optimizing loads of pallets;o Improved briefing of the staff members.
Results:o Reduction of damages within storage and transport;o 100,000€ possible savings;o 15% increase of annual rate of return.
Reuse/recycling of End-Of-Life Vehicles (ELVs) - Hungary
Problem:o Improve the efficiency of the dismantling of ELVs;
Measures:o New high-tech ICT based solution to select, separate and
reutilize valuable parts from the ELVs;o Increasing the communication among SMEs.
Results (in a particular company):o Average ELVs dismantled per day increased from 5 to 7-8;o The value of the selected and dismantled car parts increased
about 80%;o The trust and cooperation among similar SMEs has increased.
INNOVATION VOUCHERS
Innovation vouchers for manufacturing SMEs
Access to technical and business expertise on recycling and resource efficiencyo Analysis of material flows;o Assessment of savings potentials;o Life-cycle analysis and eco-design support;o Incorporation of recycled content into products;o Implementation of technological innovation measures;o Management of eco-innovation and financing solutions.
French call opened in April 2010
German call opened in September 2010
UK, Italy, Navarra planned
for autumn 2010
Valencia planned for beginning 2011
REMake: Be more profitable,
by simply using less resources
www.europe-innova.eu/remake