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The REMake project: Recycling and resource efficiency in manufacturing Forum on Environmental Goods & Services and Green Business Models Brussels, 15 October.

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Presentation on theme: "The REMake project: Recycling and resource efficiency in manufacturing Forum on Environmental Goods & Services and Green Business Models Brussels, 15 October."— Presentation transcript:

1 The REMake project: Recycling and resource efficiency in manufacturing Forum on Environmental Goods & Services and Green Business Models Brussels, 15 October 2010

2 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.

3 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.

4 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.

5 CASE STUDIES

6 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.

7 Brecon Mineral Water - UK Problem: 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.

8 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 CO 2 emissions avoided; o Savings in cumulative cost and raw materials over the parts produced each year.

9 Metal processor - Germany Problem: 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.

10 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.

11 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.

12 INNOVATION VOUCHERS

13 Innovation vouchers for manufacturing SMEs Access to technical and business expertise on recycling and resource efficiency o 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.

14 French call opened in April 2010 German call opened in September 2010 UK, Italy, Navarra planned for autumn 2010 Valencia planned for beginning 2011

15 REMake: Be more profitable, by simply using less resources


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