NI Chamber Energy Forum 2016/2017 Inclusive value chain redesign - - PowerPoint PPT Presentation

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NI Chamber Energy Forum 2016/2017 Inclusive value chain redesign - - PowerPoint PPT Presentation

May 25, 2023 194 likes •672 views

NI Chamber Energy Forum 2016/2017 Inclusive value chain redesign Ton van Keken SVP Operations EMEA 1 Inventor of modular carpet Nasdaq listed Sales $1,1 billion Employees 3.800 6 Factories on 4 continents One day people

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NI Chamber Energy Forum 2016/2017 Inclusive value chain redesign

Ton van Keken SVP Operations EMEA

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  • Inventor of modular carpet
  • Nasdaq listed
  • Sales $1,1 billion
  • Employees 3.800
  • 6 Factories on 4 continents
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“One day people like me will go to jail”

Ray Anderson Oprichter, Interface

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Journey to Zero: The seven fronts

ELIMINATE WASTE BENIGN EMISSIONS RENEWABLE ENERGY CLOSING THE LOOP RESOURCE EFFICIENT TRANSPORTATION SENSITISING STAKEHOLDERS REDESIGN COMMERCE

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68% 9% 8% 8% 7%

Raw Materials Interface Manufacturing Use & Maintenance End of Life Interface Transportation

Transparancy

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68% 9% 8% 8% 7%

Raw Materials Interface Manufacturing Use & Maintenance End of Life Interface Transportation

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Biomimicry – Learning from nature

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Towards zero installation waste using Random Design

Normal carpet tile 3 - 4% Average wastage Broadloom 12% Random carpet tile 1 - 2%

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Use less yarn Use recycled yarn Invent a new yarn

Three ways to reduce the biggest impact

  • f a carpet tile:
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Use less yarn

Microtuft: Around 50% less yarn

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ReUse

Social hubs-sorting:

  • Reuse
  • Recycling
  • Waste-to-energy

ReEntry Hub Veenendaal, the Netherlands Greenstream Recycling, Wales

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Insert background Image here

ReEntry 2.0 recycling Scherpenzeel

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Fluff Separated

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Recycled backing crumb

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Fishing nets to carpet

Aquafil’s yarn is made with 50% pre-consumer and 50% post-consumer recycled material

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Networks

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Philippines and Cameroon

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Fotosfera is our first product using bio- based nylon yarn

63% bio-based yarn

Invent a new yarn

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  • Glue-free installation
  • Virtually zero VOCs
  • Fast, clean and easy
  • Eases re-use and

recycling

TacTiles™

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RECYCLED PVB ADHESIVE

  • Recycled content
  • Cost advantage

conf nfide idential ntial

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FACTORIES TO ZERO

2020

PEOPLE PRODUCTS TO ZERO SUPPLIERS TO ZERO

Pathways to 2020 - What’s Left to Be Done

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92% 84% 45% 91% 87% NOW

Zero non renewable energy Zero process water in manufacturing Zero waste will leave our factories

Factories to Zero 3 Goals

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Energy: sustainability and costs

Year Electricity SPZ Electricity CAV Electricity total Gas SPZ Gas CAV Gas total 2015 9.040.656 kWh 1.625.998 kWh 10.666.654 kWh 1.420.908 m² 92.778 m² 1.513.686 m² Electricity SPZ Costs Electricity CAV Costs Electricity total costs Gas SPZ Costs Gas CAV Costs Gas total costs Total energy cost 813.659 € 146.340 € 959.999 € 554.154 € 36.183 € 590.338 € 1.550.336 €

SPZ: Plant in Scherpenzeel, The Netherlands Cav: Plant in Craigavon , NI

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Thermal isolation project 22.000m3 annual gas usage reduction

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LED lighting

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Our new Pre-coat process consumes 50% less gas per m2

New pre-coat manufacturing line

New pre-coat line 360.000m3 annual gas usage saving

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By recovering rejected heat and reusing it in our factory heating cycle allowed us?

Heat Recovery From The Compressed Air System

  • To further improve the overall efficiency of the compressed air system
  • To reduce our factory`s total energy heating consumption by 28%
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Project CEA-EU-0017 New GA55kw VSD Atlas Capco Air compressor Installed Recover Heat From Compressor & Duct into factory

  • Heat outlet ducting Installed from the

compressor into the factory which creates an invisible warm air curtain reducing the factory's heating costs

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2016 Savings Up To Wk32

Frequent open & close

  • peration of the speed door

5°c 20°c

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92% 84% 45% 91% 87% NOW

Factories to Zero Renewable Energy Leadership

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Green gas

Netherlands: Biogas from fish waste

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Factory & Warehouse Proposal

CLINT Reversible Heat Pump Air / Water System 570 Kwh Heating Energy & 490 Kwh Cooling Energy

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  • Uses Non – Ozone depleting refrigerant R410A
  • Heating Energy 570 Kwh / Cooling Energy 490 Kwh
  • 100% Green Electricity
  • RIF : Power factor Correction 15% reduction of input current
  • Electronic soft start reduces starting current by 30%
  • Permits operation in the winter & summer with external temps

dropping to -20 oC & rising to 50 oC Our electricity is 100% renewable therefore the heat pumps have no impact on the environment. The heat which the heat pump extract`s from the air, is constantly being renewed naturally

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Annual Energy Efficiency Gain

Current Natural Gas Heating Total Kwh 1,046,259 Kwh Gas cost per kwh 0.05 Natural Gas cost GBP £52,300.00 Green Electricity Heat Pump Total Kwh 331,793 Kwh Cost per kwh 0.10 Total Green Electricity Cost : £33,179.00 Positives Kwh % reduction 46% GBP £ Gain £19,000 Please *note projected costs are based on current market share prices*

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Ultrasonic cutting

Carpet Die cut Tiles 6 cuts + waste Carpet Ultra Sonic cut Tiles 1 cut + waste

‘window waste’ with ultra sonic cutting ‘window waste’ with die cutting

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Water in closed circuit

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Zero Virgin Materials Zero Chemicals of Concern Zero Carbon Footprint

Supplies to Zero We Can’t Do This Alone

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92% 84% 45% 91% NOW

Zero carbon footprint Zero virgin raw materials

Products to Zero 4 Goals

Zero chemicals

  • f concern

Reuse/ReEntry in every market

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Technology-led carbon reductions in carpet

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Ecometrics, Dec 2015

92% reduction

in green house gas emissions 50% raw materials recycled or biobased 50% reduction in product carbon footprint

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Global projections 2020

0 waste will leave our factories 95% reduction in green house gas emissions 95% raw materials recycled or biobased 80% reduction in product carbon footprint Carpet take-back available in every market

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Business case for sustainability

  • Competitive advantages: proposition, design, function
  • Productivity gains (eg. energy, waste)
  • Internal engagement
  • Recruiting
  • Open new markets
  • Create barriers to entry
  • Reputation
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