Company-wide steering instruments and regional action programs

In line with our strategy of achieving more with less, our business sectors develop their own optimization programs, as the various production processes involved in making products such as household cleaners, skin creams or tiling adhesives suggest fundamentally different approaches for improvements.

For instance, our Laundry & Home Care business sector launched an optimization program to reduce energy use in 2012. We had the business sector externally certified in the course of matrix certification to ISO 50001, the international standard for energy management. 15 of our 28 production sites and the corporate steering unit of the business sector were already successfully certified to this standard in 2012. All other production sites will follow by the end of 2013.

We also successfully introduced sustainability scorecards at all production sites with the aim of generating further savings in energy, materials, waste, water and wastewater at our sites.

The Beauty Care business sector further boosted its added value at its eight production sites, mainly due to its successful ongoing “Total Productive Management Plus” program (see opposite page). To demonstrate our resource efficiency in production, we had six of our factories certified to ISO 50001, the energy management standard.

As a further important aspect in addition to the ecological footprint, the business sector integrated behavior-based safety training into the program. The aim is to heighten employees’ awareness of the importance of safety and health in the workplace.

Our positive experience at the Bogotá production site in Colombia prompted us to introduce similar elements at all Beauty Care sites in 2012.

We are working on the topics of resource efficiency and safety at all of the sites in our Adhesive Technologies business sector. Increased use of standardized processes and systems is another driver of continuous improvement in production. To achieve this, we are building “multi-technology sites” that help boost efficiency even more through the use of a shared infrastructure. Our largest adhesive production site is currently being constructed on the basis of this concept in Shanghai, China.

In all three business sectors, our optimization measures aim to reduce the ecological footprint within and beyond our production operations. New warehouse concepts and the production of packaging materials directly on-site where filling takes place reduce transport mileage and thus also contribute to climate protection.

Worldwide: Selected examples of contributions to resource efficiency

Bogotá, Colombia; Chonburi, Thailand; and Jasminal, Tunisia
Under the “Total Productive Management Plus” program all cosmetics plants implemented numerous further optimization measures in 2012. In addition to the site in Bogotá, two other Beauty Care sites achieved outstanding results. The factory in Thailand successfully lowered water consumption by 28 percent and waste by 21 percent. In the plant in Tunisia, water consumption was reduced by 7 percent and waste by 22 percent.

Port Said, Egypt
The laundry detergent site reduced the amount of electricity used for the warehouse by more than 80 percent by installing a transparent roof and making use of daylight. The site also decreased its water consumption for powder production by 8 percent by reusing water from the liquid production operations.

Düsseldorf, Germany
Following its modernization, the Cooling Tower 1 reduces the temperature by a full ten degrees Celsius instead of the previous six through evaporation. At the same time, it saves 30,000 kilowatt hours in electricity per year.

Düsseldorf, Germany
The laundry detergent production facilities include a bottle blow molding line with four compressors. Thanks to the installation of an additional, higher-level control system, a rotating principle has been introduced where only one or two compressors now generate the required compressed air while the compressors that are not required are switched off and disconnected from the power supply. This can cut the annual electricity demand for compressed air generation in the bottle blow molding line by 38 percent.

Ratibor, Poland
The laundry detergent site recovers the waste heat emitted from its sulfonation system in the spray tower which is used to produce powder detergents. This made it possible to reduce the energy consumption of the spray tower by 20 percent.

St. Louis, Missouri, USA
The laundry detergent site reduced its energy usage by 5 percent by optimizing its compressed air system. This included installation of a highly efficient air compressor with speed control and inspections reduce losses in the compressed air system.

Salamanca, Mexico
The adhesive site uses all of the wastewater for the cooling tower, which helped to lower water consumption by 35 percent. Steam boiler optimization reduced natural gas consumption by 70 percent.

Resource-efficient adhesives production

In mid-2013, our largest adhesive plant in Shanghai, China, will begin serving the market for industrial adhesive technologies in the Asia/Pacific region. Through further development of production processes and workflows, the site’s water and energy usage will reflect the latest state of the art in resource efficiency.

Last updated: March 6, 2013