Resource Efficiency Seminar Eco Design

Content What is eco design? What is eco design? Benefits of eco design? Benefits of eco design? Environment or Economics? Environment or Economics? Example Larkin Engineering Larkin Engineering How to implement eco design How to implement eco design

Global warming

co Design

What is Eco design ”the systematic consideration, during new production and process development, of design issues associated with environmental safety and health over the full product life cycle”

Benefits of Eco design Products designed with environmental considerations in mind will result in products which are less costly to own and operate and less damaging to the environment.

Case study

Larkin Engineering Company background: Larkin Engineering is a small company based in Tuam, Co. Galway, which manufactures street furniture. The company is committed to reducing the environmental impact of their activity and products. A few projects have been going on in a few areas: Design for Environment (DfE), rain water harvesting, waste minimisation, energy savings, extending product life.

Timetable carousal

The LCA/Eco Design Initiative Why: To improve the environmental performance of their products but also to gain new customers and to enter new markets What: Re-designed the company products using eco design techniques Introduced a rainwater harvesting system for the water jet cutter Identified and eliminated the energy losses due to the compressor improper use Carried out an LCA study to compare old design with new design

Background 1. Old design, product made of metal, manufactured in China 2. New design, product made of virgin polyethylene (PE) 3. The same new design, product made of recycled polyethylene

Flow diagram for metal carousel

Flow diagram virgin polyethylene

Flow diagram recycled polyethylene

Environmental benefits Global warming and non-renewable fossil fuel are the two indicators: Metal carousel the highest impact (22.06kg CO 2 eq, 294.6MJ eq). Carousel made of virgin PE lower impact (7.66kg CO 2 eq, MJ eq) Carousel made of recycled PE the lowest impact (3.48kg CO 2 eq, MJ eq The impact category ‘non-renewable fossil fuel’ for the house is 60,900MJ eq As seen the fuel indicator outlined above for the three alternatives is equivalent to the following: 2,000 pieces made from metal plastic mitigates to enough heat for 10.5 houses for one year 2,000 pieces of virgin carousel will provide sufficient energy to heat 3.5 houses for one year. 2,000 pieces from recycled polyethylene mitigates the effect of heating 2 such houses for one year.

Economic benefits Previous price from China: €50.30 Manufactured in Tuam: €32 1. Ireland : 2. Portugal: 3. United Kingdom:

120 Litre Jumbo bin

Background Old design, before the DfE training New design, after the application of DfE techniques Refurbished bin, a new solution considered by the company. Old bins are taken back, refurbished and sent back to the customer.

Flow diagram for 120 litre Jumbo bin

Eco design savings are as follows: 120 litre Jumbo Bin 38% saving on raw material. Financial saving of €40 per bin. 20% reduction in VOC emissions compared to 2008 figures. 30% reduction in plant operating hours due top efficient world class manufacturing techniques Management have committed to a sustainable business model and are applying eco-design, take-back of old and damaged bins as well as having achieved accreditation to ISO14001 in November 2011.

JFC Manufacturing Equivalent of 26% less plastic is used to supply water to the same number of cow. New product is 100% recyclable Stick on labels have been removed.

Life cycle assessment of RADICA Scenario 1: Use RADICA to decontaminate 100 mattresses in house Scenario 2: Use washer/dryer system to decontaminate off site using traditional disinfection and detergents. Energy: 15% reduction in electricity consumption

LCA Comparison Environmental impact: RADICA would require the equivalent of 3 trees to absorb the CO 2 produced Off site decontamination would require 165 tress to absorb the CO 2 produced. Lessons: Use different type of plastic or a permanent solution

Introducing eco design to a company may come from management down to the designers or the designers may introduce it incrementally and build expertise and experience How to Implement Eco Design in Your Business

Steps 1. Convince senior management of the importance of eco design to business success 2. Build the design team 3. Introduce eco design in pilot projects

1. Convince management Arguments in favour of eco design include: It is cost effective It offers new solutions for products e.g. savings in weight and volume, energy efficiency It provides opportunities for value creation e.g. reuse and recycling It is good for marketing – better company image, competitive advantage Being proactive means cost savings and meeting forthcoming legislation requirement in the long term

2: Build the design team Eco- design team Product design Environmental mgmt. ProductionMarketingPurchasing Supply chain, cost targets Market requests, competitors Technical input Creative solutions

3:Start DfE pilot project Define scope and taskEnvironmental impact of reference productGenerate and select ideaWork out the solutionComplete final assessmentIntroduce to marketMonitor

Eco Design Techniques Design for material minimisation Design for minimisation of hazardous materials Design for energy efficiency Design for waste reduction Design for cleaner production Design for durability Design for disassembly Design for serviceability Design for reuse Design for remanufacturing Design for recycling

Design for waste reduction What it is: The practice of designing a product so that its entry to the waste stream is postponed by reuse, remanufacture and recycling Principles of technique: The same principles as listed in the following techniques: Design for material minimisation Design for durability Design for reuse Design for remanufacture Design for recycling

Design for Disassembly What it is: The practice of using assembly methods and configurations that allow cost-effective separation and recovery of reusable components and materials Type 1: disassembly for reuse, remanufacturing and service – concerned with the careful removal of parts for reuse. Type 2: disassembly for recycling and disposal – not concerned with the integrity of the parts or the fasteners. Example: Smart cars Smart cars are designed for disassembly so that individual parts can be replaced if necessary and the discarded parts can be recycled It is 95% recyclable

Thank you!