Introduction to EcoDesign Adopting EcoDesign measures for considering environmental issues through the whole product chain EcoDesign seeks to prevent pollution from the source during product development EcoDesign is a way of thinking – and needs appropriate tools and methods EcoDesign is a business opportunity

Life cycle thinking A product’s life cycle comprises ... raw materials acquisition components production product assembly distribution, retail, packaging product use (refurbishment) (reuse) end-of-life plus: all related transports! Cradle to grave approach to assess the environmental performance of products and services

Product design effect on environment Production, distribution, use and end of life management of energy-using products causing impacts on the environment Approx. 80% of all product-related environmental impacts are determined during the product design phase Considering environmental aspects in the design phase is a effective approach to improve products

Entry points for EcoDesign Manufacturing. Increase efficiency Procurement. Reduce auxiliaries variety, avoid hazardous materials Marketing. Green sells better Research and development. Create innovative products Environment, Health & Safety (EHS). Improve production, improve working conditions Quality management. Reliable products instead of throw-away products

Benefits from Being Green The business point of view Competition Market pressure Public opinion Customer requirements Customer safety Green sells better Innovation Cost savings Risk reduction Employee motivation Ecolabeling programmes Companies responsibility Corporative communication Supply chain relationship Product quality Legislative regulations Voluntary agreement

Benefits from Being Green The business case: Better Energy Systems (UK) Philosophy: “Better Energy Systems is a leading manufacturer of portable renewable energy products. We are committed to using the most effective means to develop and distribute environmentally conscious products to the global economy.” “Through our work we aim to educate the consumer on the functionality and profitability of environmentally designed products.” In contradiction to frequently heard argument: “customer does not ask for green products”

Benefits from Being Green The business case: Better Energy Systems (UK) Product: Solio – Solar Charger for mobile devices Combining aesthetic appeal with being green: “cool and environmentally friendly” Macworld Best of Show Award 2005 Solar charger is a perfect product for an environmentally conscious product Plus educating the consumer through a very informative webpage: www.solio.com

Benefits from Being Green The business case: Better Energy Systems (UK) Eco-design activities: Toxicity analysis and energy assessment performed together with Fraunhofer IZM Identifying improvement potentials “give more than we take” philosophy targets at: “over its lifetime, Solio will ideally produce more energy than energy used in its construction.” CO2 neutral production by tree planting in developing countries (FutureForests)

Environmental work in business IPP related environmental work is based on life cycle thinking: Environmental Management Sysytem of own operations Systematic supplier management Integration of EcoDesign in product and process development Sound end of life practice for product

What is IPP Integrated Product Policy (IPP) is a key strategy for EU environmental policy Integrated Product Policy (IPP) seeks to minimise environmental impacts by looking at all phases of a products' life-cycle and taking action where it is most effective The life-cycle of a product covers all the areas from the extraction of natural resources, through their design, manufacture, assembly, marketing, distribution, sale and use to their eventual disposal as waste.

Aspects of IPP IPP involves many different actors such as designers, industry, marketing people, retailers and consumers. IPP attempts to stimulate each part of these individual phases to improve their environmental performance. IPP is based on a variety of tools - both voluntary and mandatory IPP include e.g. economic instruments, substance bans, voluntary agreements, environmental labelling and product design guidelines.

Subject for IPP/Ecodesign in electronics Characteristics of electronics – “green” benefits Shrinking products, from hardware to software Miniaturization Concentration (of information and data, e.g., MP3 player) Digitalization Portability Function integration (Value added functions) Electronic transport versus mechanical transport Global village – virtual global network

Green public procurement Public procurement constitutes on average around 12% of EU GDP (gross domestic product) Great potential for using public procurement to improve the environmental performance of products throughout their life cycle Product declaration / labelling a criteria in contract specifications National legislation in several EU member states require green public procurement

Benefits from Being Green Consumer Awareness Results of a study in Germany (2004): Are you willing to pay more for environmentally benign products? Note: that does not mean, that “green” products have to be more costly

EU Policy and Legislation focus: product focus: enterprise Integrated Product Policy aspect specific regulations EcoDesign: EuP framework directive (draft) energy labelling directive several directives planned already existing energy efficiency directives e-waste: WEEE material bans: RoHS (automotives: ELV) environmental management: EMAS EMAS Environmental management and audit schema EuP Energy using Products

RoHS in Detail Member States shall ensure that, from 1 July 2006, new electrical and electronic equipment put on the market does not contain Lead Mercury Cadmium Hexavalent chromium Polybrominated biphenyls (PBB) or Polybrominated diphenyl ethers (PBDE) ... more substances under discussion http://europa.eu.int/comm/environment/waste/weee_index.htm

Legal bans of Hazardous substances in electronic Products and Parts Products and Product Parts with specific legal bans Electrical and electronic equipment (mercury, cadmium, lead, hexavalent chromium, PBBs, PBDEs) Electrical components (halogenated aromatic compounds) Plastic Parts (butadiene, acrylonitrile, cadmium compounds, OBDE, PeBDE) Insulation materials (CFCs and halons)

WEEE in General Take back requirements Recycling quotas Background Amount of WEEE: 6 mill tons per year in the EU Trend: 3 to 5% increase per year Collection, treatment and recovery rates low Treatment often difficult WEEE contains: heavy metals, problematic chemicals like flame retardants valuable materials like precious metals, copper, tin

WEEE in Detail Annex I A: Scope Large and small household appliances IT and telecommunications equipment Consumer and lighting equipment Electrical and electronic tools Toys, leisure and sports equipment Medical devices Monitoring and control instruments Automatic dispensers http://europa.eu.int/comm/environment/waste/weee_index.htm

WEEE in Detail Parties involved Only if you are a “distributor” or “producer” you are obliged to follow the requirements of the WEEE directive If you are a (component) supplier, the rules are not directly relevant to you … but care for the requirements, which will be passed on in the supply chain by your customers!

Rates for collection, recovery, recycling WEEE in Detail Rates for collection, recovery, recycling Separate Collection ≥ 4 kg per inhabitant and year from households (per country) Large household appl., automat. dispensers ≥ 80 w.-% recovery ≥ 75 w.-% re-use*, recycling ICT, consumer electronics ≥ 75 w.-% recovery ≥ 65 w.-% re-use*, rec. Others Small household appl., lighting equipment, electrical and electronic tools (without large-scale stationary industrial tools), toys, leisure and sports equipment monitoring and control instruments ≥ 70 w.-% recovery ≥ 50 w.-% re-use*/rec. *Until dec. 31, 2008 entirely re-used EEE not accounted for rates!

Producer responsibility WEEE in Detail Producer responsibility WEEE from private households (B2C): Producers install systems for take back free of cost for final user, at least take back from public collection points Individual or collective systems possible Producers take over cost of re-use, recycling, disposal Distributors voluntarily (but free of cost) may take back WEEE WEEE from other than private users (B2B): Producer has to offer appropriate possibility for take back for B2B customers Producer responsible for collection, re-use, recycling, disposal, and costs of „new“ WEEE

WEEE in detail Product design Encourage design and production of EEE with respect to easy dismantling and recovery Foster reuse and recycling of WEEE, components and materials Assure that design features or manufacturing processes do not hinder Reuse unless such specific design features or manufacturing processes present overriding advantages, for example, with regard to the protection of the environment and/or safety requirements. It’s up to the creativity of the member states, how to set right “measures”

Recycling technology requirements: Selective Treatment (Annex II) WEEE in Detail Recycling technology requirements: Selective Treatment (Annex II) General removal of PWBs from mobile phones Removal of PWBs larger than 10 square-cm Removal of LCDs (larger than 100 square-cm), plastics with brominated flame retardants, batteries, mercury containing components etc. etc. Remember: From 2005 on you as a manufacturer will be obliged to pay for this treatment! adapt your product design to make selective treatment an efficient process!

Product information for recyclers WEEE in Detail Product information for recyclers producers have to provide reuse and treatment information for each type of new EEE put on the market within one year after the equipment is put on the market this information shall identify, as far as it is needed by reuse centres, treatment, and recycling facilities, the different EEE components and materials, the location of dangerous substances and preparations in EEE

Product Information for Recyclers Example: Recycling passport developed in a German project Major recycler involved Excerpt from recycling passport (project PROMEKREIS)

EuP Directive in General Overview Energy using Products (EuP) directive is a framework directive which form the basis for future product specific directives The directive has been adopted 6 July 2005 Harmonization of EU laws through compliance with CE-marking EU eco-labelled products are assumed to fulfill the EuP requirements http://europa.eu.int/comm/enterprise/eco_design/index.htm

Benefits from Being Green Eco-Labels Status of eco-labelled products as of end of 2002 Country Product groups Firms Products Germany 94 995 3114 Nordic Countries 69 1275 4098 Spain 29 150 944 Austria 44 334 645 France 15 47 443 The Netherlands 257 360 EU 21 185 576 (reference: Rubik, 2004)

Benefits from Being Green Eco-Labels - Example: The “Blue Angel” First official national eco-labeling scheme worldwide, launched in 1978 About 3.800 products and services Approx. 710 label users in Germany and abroad are permitted to bear the Blue Angel Electronic product range: mobile phones, portable and stationary computers

Energy Efficiency EU Energy labelling directives Product categories   EU Energy labelling directives Product categories Refrigerators, freezers Electric ovens Air conditioner Lamps Dishwashers Washer-driers Tumble driers Washing machines (all household appliances) Example: Washing machines - Improvements achieved Water consumption for 5 kg coloured laundry: 1965: 180 l 1990: 75 l 2004: <40 l (note: label introduced 1995)

Benefits from Being Green Business point of view Be compliant! Example: Entertainment equipment OEM In December 2001 Dutch customs stopped imports of a entertainment equipment due to elevated Cadmium levels in cables, exceeding legal thresholds Consequences: serious losses for 2001 Christmas sales, OEM exchanges cables at 1.3 million devices Lessons learned: OEM launched a Green Partnership Initiative with strict requirements for suppliers being a “Green Partner” now is a major business benefit Legal compliance is a “must”! it is up to you to apply smart strategies to comply with legislation and to generate business benefits simultaneously Next: Content – What is addressed – legal framework

Communication strategy Ensure, that customers knows about our goal and visions for ecodesign Sales division include this communication in dialogue with customers Goal and visions shall be expressed in written as documentation Important to communicate progress with ecodesign in product development, neverless the results hasn’t been achieved yet A short introduction is given by the slides. Aims, complexity, organizer and the focus are clarified. The audience is addressed and advantages by taking part in the workshops are named. It’s important to put emphasis on the fact, SME playing an active roll in the workshop-programme and cooperation is needed.

The Business Case: TWINflex® developed by: Würth Elektronik printed circuit board in MicroVia technology using foil technology with flexible materials, such as polyimide or Liquid Crystal Polymer flexible in form and function: suitable for high density flexible, flex-rigid and three dimensional circuits foil circuit board could be mounted on a homogenous plastic or metal substrate © Würth Elektronik Applications Large variety of possible base substrates 2 to 6 layers Suitable for complete range of surface mount technology (including chip-on-board, flip chip, chip size packages, ball grid array) Usable for heat sink applications (automotive sector, multi-chip-modules) Conventional multilayer PCB TWINflex: substrate and circuits seperated

The Business Case: TWINflex® Environmental Aspects TWINflex® separates mechanical and electrical functions of the usual printed circuit board Expensive materials (like noble metal) can be regained in an efficient way Other materials can be dismantled easily and reused without any preparation Reduction of end-of-life costs through easy separation (preparation for WEEE implementation) Applications of harmful substances during the production-phase can be limited by TWINflex® drastically

Key issues in EcoDesign Materials (renewable resources and hazardous substances) Manufacturing processes Energy consumption (low energy consumption) End-of-life (reuse and recycle)

Materials General recommendations: Use as few different types of materials as possible Avoid dangerous and hazardous substances Avoid using materials characterized as scarce resources Use materials which can be recycled in the established recycling systems Reduce consumption of materials, avoid over-dimensioning Reduce packaging Reduce spillage and waste

Legal bans on hazardous substances Products and Product Parts with specific legal bans Electrical and electronic equipment (mercury, cadmium, lead, hexavalent chromium, PBBs, PBDEs, Sulfur hexafloride (SF6)) Batteries (mercury, cadmium, lead) Electrical components (halogenated aromatic compounds) Plastic Parts (vinyl cloride, butadiene, acrylonitrile, cadmium compounds, OBDE, PeBDE) Insulation materials (CFCs and halons)

Energy Consumption (1) Example Personal Computer Frequent-use product (maybe even “always-on”) Very complex, most of the product is electronics B2C Lifetime average 3-5 years Environmental aspects - Energy-efficiency For reasons of simplification: Focus only on energy (primary energy) as “environmental indicator” Main unit without peripheral devices (monitor, mouse, keyboard etc.)

Energy Consumption (2) In total approx. 535 kWh Personal computer Production Transportation: 50 kWh (global supply chains!) Electronic assemblies: ICs PCBs Passives / miscellaneous Motors, fans Housing, etc In total approx. 535 kWh

Energy Consumption (3) Personal computer Use-phase Depends on lifetime, use patterns, use of energy saving modes, stand-by Example: 4 years average use of a Pentium III PC In total roughly 1.600 kWh* *Note: also calculated as primary energy

Energy Consumption (4) Personal computer End-of-life Assumed: state-of-the-art recycling, recovering secondary raw materials (mainly steel, copper, precious metals, aluminium) Calculation: benefit of replacing primary material In total approx. 70 kWh Why is it so much less than the energy used for production? Recycling logistics, but even more: IC manufacturing cannot be compensated

Personal computer Lessons learned Energy Consumption (5) Personal computer Lessons learned Primary energy consumption Production Use Recycling Primary energy consumption Production Use Recycling Large influence of use patterns – use your influence on product use! Improving production is even more important! Don’t rely on proper recycling as your main eco-design activity

Summary: Get Started … 6 RE Philosophy Re-think the product and its functions, e.g. the product may be used more efficiently. Re-duce energy and material consumption throughout a product’s life cycle Re-place harmful substances with more environmentally friendly alternatives Re-cycle. Select materials that can be recycled, and build the product such that it is disassembled easier for recycling. Re-use. Design the product so parts can be reused. Re-pair. Make the product easy to repair so that the product does not yet need to be replaced. [UNEP Guide to LCM]

Eco-design tools: Checklists Example: Product use What is the product‘s energy consumption compared with competitors‘ products?  lower same higher Does your product have energy saving features? yes under development no Do you use batteries / rechargeable batteries in your product? Do you know, which rechargeable batteries for your specific application are the most environmentally benign ones? (recharge cycles, materials) Do you motivate the customer to reduce unnecessary stand-by? Are your energy saving features state of the art and easy to use?

Screening the whole product life cycle (1) MET Matrix Material Cycle (M) Energy Consumption (E) Toxic Emissions (T) Production and supply of materials and components End product manufacture Distribution to customers Product use Product end-of-life

Screening the whole product life cycle (2) …and don’t forget to consider frame work conditions Environment Business Customer 1st option 2nd option 3rd option ... nth option Benefit Societal Technical Financial Feasibility

How to do EcoDesign? A Guideline for integration eco-design in a product development process: ISO/TR 14062:2002 Provides concepts and current practices relating to integration of environmental aspects into product design and development Goal: Improvement of environmental performance of products

Decreasing influence on environmental impacts How to do EcoDesign? Stages of Product Development Process STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Decreasing influence on environmental impacts Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch By explaining the stages of the product development process the audience gets an overview on eco-design principles and can find methods and techniques fitting his product or his enterprise; important is to clarify that the presenter can’t present solutions for every eco-design task; but by giving examples and showing techniques the audience can develop own strategies and select appropriate tools STAGE 6: Product Review (reference: ISO/TR 14062:2002)

How to do EcoDesign? Eco-design activities What is the product idea? What are the priorities for this product? Totally new product or product improvement? When planning a product improvement, the former generation might be an appropriate benchmark for all improvements Overall company strategy Consider business environment: Customer / market needs, legislation, eco-label planned, market niches, competitors products… STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch STAGE 6: Product Review

How to do EcoDesign? Eco-design activities Integrate eco-design aspects when drafting the specification for a product Check feasibility (technological, financial) Apply e.g. guidelines, checklists to refine the specification Communicate with your supply chain STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch STAGE 6: Product Review

How to do EcoDesign? Eco-design activities Apply eco-design tools and data bases Find alternatives for materials to be avoided Life cycle scenarios Design for assembly / disassembly STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch STAGE 6: Product Review

How to do EcoDesign? Eco-design activities Check whether a realistic implementation of environmental requirements has been achieved Adaptations and changes in the design if necessary. Benchmark with former product generation STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch STAGE 6: Product Review

How to do EcoDesign? Eco-design activities Communicate environmental excellence of your product Communicate related features: quality, life cycle costs Raise awareness among consumers STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch STAGE 6: Product Review

How to do EcoDesign? Eco-design activities Evaluate success of the product Identify further environmental improvements for next product generation Which innovations are next? STAGE 1: Planning STAGE 2: Conceptual STAGE 3: Detailed Design Feedback / continuous STAGE 4: Testing / Prototype STAGE 5: Market launch STAGE 6: Product Review